Induction heating system travel sensor assembly

ABSTRACT

Induction heating system travel sensor assemblies are disclosed. An example induction heating system includes an induction heating device configured to move relative to a workpiece, to generate induction heat, and to direct the induction heat to the workpiece; and a travel sensor assembly configured to detect a position, movement, or direction of movement of the induction heating device relative to the workpiece, the travel sensor comprising a non-contacting detector

RELATED APPLICATIONS

This patent is a continuation of U.S. patent application Ser. No.14/280,227, filed May 16, 2014, entitled “INDUCTION HEATING SYSTEMTRAVEL SENSOR ASSEMBLY.” The entirety of U.S. patent application Ser.No. 14/280,227 is incorporated herein by reference.

BACKGROUND

The present disclosure relates generally to the art of inductionheating. More specifically, it relates to using a moveable inductionheating head assembly, a temperature sensor assembly, and a travelsensor assembly.

Induction heating may be used to pre-heat metal before welding orpost-heat the metal after welding. It is well known to weld pieces ofsteel (or other material) together. For example, pipes are often formedby taking a flat piece of steel and rolling the steel. A longitudinalweld is then made along the ends of the rolled steel, thus forming asection of pipe. A pipeline may be formed by circumferential weldingadjacent sections of pipe together. Other applications of welding steel(or other material) include ship building, railroad yards, tankertrucks, or other higher strength alloy welding.

When welding steel (or other material), it is generally desirable topre-heat the workpiece along the weld path. Pre-heating is used to raisethe temperature of the workpiece along the weld path because the fillermetal binds to the workpiece better when the weld path is pre-heated,particularly when high-alloy steel is being welded. Without pre-heating,there is a greater likelihood that the filler metal will not properlybind with the workpiece, and a crack may form, for example. Generally,the steel is preheated to about 300° F. prior to welding.

Conventional pre-heating techniques use “rose buds” (gas-fired flametorches), resistance “chicklets”, or induction heating blankets topre-heat the steel. For example, rosebuds may be placed along the weldpath, typically one rosebud on each side of the weld path, or onecovering both sides of the weld path, for every 3 to 6 feet. Therosebuds are left in place a relatively long period of time (e.g., up totwo hours for 3″ thick steel). After the weld path has been pre-heated,the rose buds are removed and the weld is performed before the weld pathcools.

Induction heating blankets are used to pre-heat a weld by wrapping aninduction blanket (e.g., an induction cable inside a thermally safematerial), and inducing current in the workpiece. Induction heating canbe a fast and reliable way to pre-heat, particularly on stationaryworkpieces. However, induction blankets have certain challenges whenused with moving workpieces, and some pipe welding applications have afixed position welder with a pipe that moves or rotates past the weldlocation. Liquid-cooled cables offer flexibility in coil configurations,but have similar issues with rotating pipes rolling up cables or wearingthrough the insulation.

Other methods of pre-heating a weld path include placing the entireworkpiece in an oven (which takes as long as using a rosebud), inductionheating, or resistance heating wires. When pre-heating with theseconventional techniques, the heating device is placed at one location onthe weld path until that location is heated. Then, the weld is performedand the heating device is moved.

Often, these conventional approaches for pre-heating workpieces usevarious methods (e.g., temperature sensitive crayons) for monitoring thetemperature of the workpieces, but do not have temperature feedback forcontrolling the power source. Accordingly, a system for pre-heating aweld path and for incorporating temperature and/or travel feedback intothe control of the pre-heating is desirable.

BRIEF DESCRIPTION

Embodiments described herein include an induction heating system havingan induction heating head assembly configured to move relative to aworkpiece. The induction heating system may also include a temperaturesensor assembly configured to detect a temperature of the workpieceand/or a travel sensor assembly configured to detect a position,movement, or direction of movement of the induction heating headassembly relative to the workpiece, and to transmit feedback signals toa controller configured to adjust the power provided to the inductionheating head assembly by a power source based at least in part on thefeedback signals. In certain embodiments, the induction heating systemmay also include a connection box configured to receive the feedbacksignals, to perform certain conversions of the feedback signals, and toprovide the feedback signals to the power source. Furthermore, incertain embodiments, the induction heating system may include aninductor stand assembly configured to hold the induction heating headassembly against the workpiece.

DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a perspective view of an induction heating system inaccordance with embodiments of the present disclosure;

FIG. 2 is a block diagram of a power source of the induction heatingsystem in accordance with embodiments of the present disclosure;

FIG. 3 is a top perspective view of an induction heating head assemblyof the induction heating system in accordance with embodiments of thepresent disclosure;

FIG. 4 is a bottom perspective view of the induction heating headassembly of FIG. 3 in accordance with embodiments of the presentdisclosure;

FIG. 5 is an exploded perspective view of the induction heating headassembly of FIG. 3, illustrating brackets and an adjustable connectionmechanism, in accordance with embodiments of the present disclosure;

FIG. 6 is a perspective view of the induction heating head assembly ofFIG. 3, illustrating an adjustable handle in an adjusted position, inaccordance with embodiments of the present disclosure;

FIG. 7A is a partial cutaway perspective view of a main housing and aninduction head control assembly of the induction heating head assemblyin accordance with embodiments of the present disclosure;

FIG. 7B is a perspective view of the induction heating head assembly inaccordance with embodiments of the present disclosure;

FIG. 7C is a cutaway side view of the induction heating head assembly inaccordance with embodiments of the present disclosure;

FIG. 8 is an exploded view of an induction head of the induction heatinghead assembly in accordance with embodiments of the present disclosure;

FIG. 9 is a perspective view of a conductive coil of the induction headof FIG. 8 in accordance with embodiments of the present disclosure;

FIGS. 10A through 10C are perspective views of an alternative embodimentof the conductive coil of FIG. 9;

FIG. 11 is a side view of a main housing and temperature sensor assemblyof an embodiment of the induction heating head assembly in accordancewith embodiments of the present disclosure;

FIG. 12 is a zoomed in perspective view of first and second brackets ofthe temperature sensor assembly, an adjustable connection mechanism ofthe temperature sensor assembly, and the main housing of the inductionheating head assembly in accordance with embodiments of the presentdisclosure;

FIG. 13 is an exploded perspective view of the first and second bracketsof the temperature sensor assembly, the adjustable connection mechanismof the temperature sensor assembly, and the main housing of theinduction heating head assembly in accordance with embodiments of thepresent disclosure;

FIG. 14 is front view of the temperature sensor assembly and the mainhousing of the induction heating head assembly in accordance withembodiments of the present disclosure;

FIG. 15 is a perspective view of a bracket of the temperature sensorassembly in accordance with embodiments of the present disclosure;

FIG. 16 is a perspective view of the temperature sensor assembly inaccordance with embodiments of the present disclosure;

FIG. 17A is a partial cutaway side view of the temperature sensorassembly in accordance with embodiments of the present disclosure;

FIG. 17B is a perspective view of the temperature sensor assembly inaccordance with embodiments of the present disclosure;

FIG. 17C is an exploded perspective view of the temperature sensorassembly in accordance with embodiments of the present disclosure;

FIG. 18 is a side view of the induction heating head assembly having afirst temperature sensor assembly attached to a front side of theinduction heating head assembly and a second temperature sensor assemblyattached to a back side of the induction heating head assembly inaccordance with embodiments of the present disclosure;

FIG. 19 is a front bottom perspective view of a travel sensor assemblyand the main housing of the induction heating head assembly inaccordance with embodiments of the present disclosure;

FIG. 20 is a back bottom perspective view of the travel sensor assemblyand the main housing of the induction heating head assembly inaccordance with embodiments of the present disclosure;

FIG. 21 is a zoomed in perspective view of a tensioning mechanism of thetravel sensor assembly in accordance with embodiments of the presentdisclosure;

FIG. 22 is a partial cutaway side view of the travel sensor assemblyincluding an optical sensor in accordance with embodiments of thepresent disclosure;

FIG. 23 is a partial cutaway side view of the travel sensor assemblyincluding a tachometer in accordance with embodiments of the presentdisclosure;

FIG. 24 is a partial cutaway side view of the travel sensor assemblyincluding an accelerometer in accordance with embodiments of the presentdisclosure;

FIG. 25 is a side view of an inductor stand configured to hold theinduction heating head assembly in a relatively fixed position inaccordance with embodiments of the present disclosure;

FIG. 26 is an exploded perspective view of the inductor stand of FIG.25;

FIG. 27 is a side view of another inductor stand configured to hold theinduction heating head assembly in a relatively fixed position inaccordance with embodiments of the present disclosure;

FIG. 28 is a partial perspective view of a main inductor interface bodyof the inductor stand of FIG. 27;

FIG. 29 is a partial cutaway perspective view of an angular alignmentplate of the main inductor interface body and an adjustable tubeassembly of the inductor stand of FIG. 27;

FIG. 30 is a perspective view of the power source including a removableconnection box and a removable air filter assembly in accordance withembodiments of the present disclosure;

FIG. 31 is a partial perspective view of the removable connection boxand the removable air filter assembly of FIG. 30;

FIG. 32 is another partial perspective view of the removable connectionbox and the removable air filter assembly of FIG. 30;

FIG. 33A is a perspective view of the removable connection box with anaccess door of the connection box removed for illustration purposes inaccordance with embodiments of the present disclosure;

FIG. 33B is an exploded perspective view of the connection box inaccordance with embodiments of the present disclosure;

FIG. 34 is a partial perspective view of the power source of FIG. 30,illustrating connection blocks to which the removable connection box maybe communicatively coupled; and

FIG. 35 is a graph of a temperature ramp that controller circuitry ofthe power source may utilize while controlling output power from thepower source in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

Embodiments described herein include an induction heating systemincluding a power source and an induction head system having a coil thatis controlled by the power source. The power source is configured toprovide power for induction heating, and the induction heating headassembly is configured to induce heat in a workpiece, such as pipe. Acoil within the induction heating head assembly is tuned to the powersource and is configured to deliver a sufficient amount of power to theworkpiece to adequately pre-heat and/or post-heat the workpiece withoutusing an impedance matching transformer while operating within workingoutput parameters (voltage, amperage, frequency, and so forth) of thepower source. Thus, the induction heating system described hereineliminates the need for a transformer disposed between the inductionheating head assembly and the power source.

FIG. 1 is a perspective view of an embodiment of an induction heatingsystem 10 in accordance with the present disclosure. As illustrated inFIG. 1, the induction heating system 10 includes a power source 12 andan induction heating head assembly 14 that function together to pre-heatand/or post-heat a workpiece 16, such as the pipe illustrated in FIG. 1.As described in greater detail herein, the induction heating headassembly 14 is configured to move relative to surfaces of workpieces 16to enable induction heating to be performed efficiently across a varietyof workpieces 16. For example, in certain embodiments, the inductionheating head assembly 14 includes wheels (or some other contactingfeature), and is capable of moving with respect to the workpiece 16 (or,alternatively, remaining relatively stationary while the workpiece 16moves with respect to it), while the wheels roll across a surface of theworkpiece 16. In other embodiments, the induction heating head assembly14 may be moved with respect to the workpiece 16 (or, alternatively,remain relatively stationary while the workpiece 16 moves with respectto it) without contacting the workpiece 16. The induction heating headassembly 14 may be moveable in many different ways with respect to theworkpiece 16. For example, when the workpiece 16 is a relatively flatplate, the induction heating head assembly 14 may translate along aplane generally parallel to a surface of the flat plate or,alternatively, remain relatively stationary while the flat platetranslates with respect to the induction heating head assembly 14.However, when the workpiece 16 is pipe, as illustrated in FIG. 1, theinduction heating head assembly 14 may move in a generally circularpattern along the outer circumference of the pipe or, alternatively,remain relatively stationary while the pipe is rotated and the outercircumference of the pipe moves with respect to the induction heatinghead assembly 14.

As illustrated in FIG. 1, the power source 12 and the induction heatinghead assembly 14 are connected together via cable 22 to enable thetransmission of power from the power source 12 to the induction heatinghead assembly 14. In certain embodiments, the cable 22 also facilitatesfeedback to be sent from the induction heating head assembly 14 to thepower source 12, wherein the feedback is used by the power source 12 toadjust the power provided to the induction heating head assembly 14.

As described in greater detail herein, the induction heating headassembly 14 generally includes a cable strain relief cover 24, a mainhousing 26, a temperature sensor assembly 28, and a travel sensorassembly 30. Although illustrated in figures and described herein asbeing part of the induction heating head assembly 14, in certainembodiments, the temperature sensor assembly 28 and/or the travel sensorassembly 30 may function separate from the induction heating headassembly 14 (i.e., not be attached to the main housing 26 of theinduction heating head assembly 14). In general, feedback from thetemperature sensor assembly 28 and the travel sensor assembly 30 aresent to the power source 12 via first and second control cables 18 and20, respectively, and the cable strain relief cover 24 receives thepower from the power source 12 via a third cable bundle 22. Inparticular, the temperature sensor assembly 28 includes a temperaturesensor for detecting temperature at a location on the workpiece 16, andthe temperature sensor assembly 28 is configured to send feedbacksignals relating to the temperature of the workpiece 16 to the powersource 12, which uses these temperature feedback signals to adjust thepower that is sent to the cable strain relief cover 24. In addition, thetravel sensor assembly 30 includes a travel sensor for detectingposition and/or movement (e.g., speed, acceleration, direction,distance, and so forth) of the induction heating head assembly 14 withrespect to the workpiece 16, and the travel sensor assembly 30 isconfigured to send feedback signals relating to the detected positionand/or movement of the induction heating head assembly 14 to the powersource 12, which uses these position and/or movement feedback signals toadjust the power that is sent to the cable strain relief cover 24. Ingeneral, the feedback from the temperature sensor assembly 28 and thetravel sensor assembly 30 may enable a number of control techniques thata controller of the power source 12 may implement, such as maintainingcertain temperatures of the workpiece 16, increasing or decreasing thetemperature of the workpiece 16, maintaining a given amount of heatinput to a desired target location on the workpiece 16, varying anamount of heat input among various locations on the workpiece 16,varying an amount of heat input based on operating parameters (e.g.,heating parameters, and so forth), and other control objectives.

In certain embodiments, the power source 12 provides alternating current(AC) power to the induction heating head assembly 14 via the cablebundle 22. The AC power provided to the induction heating head assembly14 produces an AC magnetic field that induces an electromagnetic fieldinto the workpiece 16, thereby causing the workpiece 16 to be heated. Asdescribed in greater detail herein, in certain embodiments, theinduction heating head assembly 14 includes a coil with an optional fluxconcentrator mounted in an enclosure. In certain embodiments, the coilhas a compact, multi-turn design and may accommodate a range of pipediameters while providing a wide, consistent heat zone. In certainembodiments, the induction heating head assembly 14 may enable inductionheating to be intensified at various locations with respect toorthogonal axes (e.g., a vertical axis 32 and perpendicular horizontalaxes 34, 36) of the induction heating head assembly 14. For example, incertain embodiments, the induction heating may be intensified more at aleading side 38 (i.e., a side ahead of a direction of movement) or at atrailing side 40 (i.e., a side behind a direction of movement) of theinduction heating head assembly 14, and/or intensified more at lateralsides 42, 44 (i.e., sides generally parallel to a direction of movement)of the induction heating head assembly 14.

As described above, the power source 12 may be any power source capableof outputting sufficient power to the induction heating head assembly 14to produce the induction heating of the workpiece 16. For example, incertain embodiments, the power source 12 may be capable of outputtingpower up to 300 amperes, however, other embodiments may be capable ofgenerating greater output current (e.g., up to 350 amperes, or evengreater). In certain embodiments, the power source 12 includes convertercircuitry as described herein, which provides an AC output that isapplied to the induction heating head assembly 14. FIG. 2 illustratesthe internal components of an exemplary switched power source 12 inaccordance with the present disclosure. As illustrated in FIG. 2, thepower source 12 includes rectifier circuitry 46, inverter circuitry 48,controller circuitry 50, and output circuitry 52. The embodiment of thepower source 12 illustrated in FIG. 2 is merely exemplary and notintended to be limiting as other topologies and circuitry may be used inother embodiments. In certain embodiments, the output circuitry 52 doesnot include a matching transformer. Furthermore, in certain embodiments,the controller circuitry 50 may be located in a box (e.g., separatehousing) external to a housing of the power source 12.

In certain embodiments, the power source 12 may provide approximately 35kilowatts (kW) of output power 54 at approximately 700 volts andapproximately 5-30 kilohertz (kHz) (at approximately 350 amps peroutput). The power source 12 is capable of delivering partial poweroutput 54 to the workpiece 16 if an output voltage or current limit,power limit, or power factor limit is reached. In certain embodiments,the input power 56 may be in a range of approximately 400-575 volts. Itwill be appreciated that larger or smaller power supplies 12 may beused, such as power supplies 12 capable of producing approximately 50 kWor greater, between approximately 30 kW and approximately 40 kW, betweenapproximately 40 kW and approximately 60 kW, and so forth, of outputpower 54. Similarly, power supplies 12 capable of producing lower thanapproximately 20 kW, between approximately 10 kW and approximately 30kW, less than approximately 10 kW, less than approximately 5 kW, or evenlower, of output power 54 may be used. In general, in most embodiments,the power output 54 produced by the power source 12 is greater than 1kW. In certain embodiments, the power source 12 includes connections formultiple power outputs 54, with each power output 54 being coupled(e.g., via cable(s) 22 illustrated in FIG. 1) to a respective inductionheating head assembly 14. In other embodiments, multiple power sources12 may be used, with the power outputs 54 of the power sources 12 beingcoupled to a respective induction heating head assembly 14.

It will be appreciated that, in certain embodiments, the controllercircuitry 50 of the power source 12 may include a processor 58configured to execute instructions and/or operate on data stored in amemory 60. The memory 60 may be any suitable article of manufacture thatincludes tangible, non-transitory computer-readable media to store theinstructions or data, such as random-access memory, read-only memory,rewritable flash memory, hard drives, optical discs, and so forth. Byway of example, a computer program product containing the instructionsmay include an operating system or an application program. Thecontroller circuitry 50 may, for example, include instructions forcontrolling the input rectifier circuitry 46, the inverter circuitry 48,the output circuitry 52, and other circuitry of the power source 12, tomodify the output power 54 of the power source 12, thereby modifying thepower delivered to the induction heating head assembly 14 for thepurpose of induction heating the workpiece 16. As described in greaterdetail herein, the controller circuitry 50 may modify the output power54 provided to the induction heating head assembly 14 based at least inpart on feedback signals received from the temperature sensor assembly28 and/or the travel sensor assembly 30. Although illustrated in FIG. 2and described herein as being part of the power source 12, in otherembodiments, the controller circuitry 50 may be part of a separatecontrol module (i.e., having a separate housing or enclosure) thatcommunicates with the power source 12 to control the power supplied tothe induction heating head assembly 14.

FIG. 3 is a top perspective view of an embodiment of the inductionheating head assembly 14, illustrating the main components of theinduction heating head assembly 14, namely the cable strain relief cover24, the main housing 26, the temperature sensor assembly 28, and thetravel sensor assembly 30. Also illustrated in FIG. 3 are a power supplyline 62 and a power return line 64 of the cable 22. The power lines 62,64 of the cable bundle 22 provide the power that is used for inductionheating to the cable strain relief cover 24. In certain embodiments, thepower lines 62, 64 may be liquid cooled. In addition, in certainembodiments, the cable bundle 22 includes a thermocouple cable 65 thatfacilitates communication of thermocouple feedback to the controllercircuitry 50 of the power source 12.

Also illustrated in FIG. 3 is the cable 20 connected to a connector 66of the travel sensor assembly 30. The connector 66 may be any suitableconnector, such as a multi-pin connector, for connecting to the cable 20such that control feedback from the travel sensor assembly 30 may becommunicated back to the controller circuitry 50 of the power source 12.FIG. 3 also illustrates the temperature sensor assembly 28 having aconnector 68 that is substantially similar to the connector of thetravel sensor assembly 30. Similarly, the connector 68 may be anysuitable connector, such as a multi-pin connector, for connecting to thecable 18 such that control feedback from the temperature sensor assembly28 may be communicated back to the controller circuitry 50 of the powersource 12. FIG. 3 also illustrates that the temperature sensor assembly28 includes a separate air cable connector 70 for connecting to an aircable (not shown) such that a supply of filtered air may be delivered tothe temperature sensor assembly 28. In certain embodiments, the airdelivered to the temperature sensor assembly 28 may be used to cool thetemperature sensor(s) of the temperature sensor assembly 28, as well asbeing used by the temperature sensor assembly 28 to help prevent debrisand smoke generated from the induction heating operation and/or awelding operation performed on the workpiece 16 from entering thetemperature sensor assembly 28, thereby protecting and cleaning theinternal components of the temperature sensor assembly 28. In certainembodiments, the cable 18 that is connected to the connector 68 of thetemperature sensor assembly 28, an air cable (not shown) that isconnected to the air cable connector 70, and any other cables connectingthe temperature sensor assembly 28 to the controller circuitry 50 of thepower source 12 may be assembled in a common cable cover assembly that,in certain embodiments, includes a zippered sheath such that the cablesmay be consolidated within the common cable cover assembly. Althoughillustrated as having connectors 66, 68, 70 that facilitate connectingthe power source 12 to the assemblies 28, 30 with the cables 18, 20, 22,in other embodiments, the cabling connecting the power source 12 to theassemblies 28, 30 may be hard wired, obviating the need for connectors.

FIG. 3 also illustrates a handle 72 that is coupled to the main housing26 of the induction heating head assembly 14. In general, the handle 72is used to cause the induction heating head assembly 14 to move withrespect to the workpiece 16. More specifically, forces may be impartedupon on the main housing 26 to cause the induction heating head assembly14 to move across the workpiece 16. In certain embodiments, the handle72 may be manipulated by (e.g., held in a hand of) a person. However, inother embodiments, the handle 72 may be attached to a robotic system(not shown) that is used to control the movement of the inductionheating head assembly 14. In such an embodiment, the power source 12 maycommunicate control and feedback signals between the robotic system toenable the power source 12 and the robotic system to cooperate tocontrol the movement (e.g., position, velocity, acceleration, and soforth) of the induction heating head assembly 14 in conjunction withother parameters of the induction heating head assembly 14, such astemperatures of the workpiece 16, rate of induction heating generated bythe induction heating head assembly 14, and parameters of a weldingoperation being performed on the workpiece 16 (e.g., current, voltage,frequency, and so forth), among others.

In other embodiments, the induction heating head assembly 14 may remainrelatively stationary while the workpiece 16 moves with respect to theinduction heating head assembly 14. For example, in certain embodiments,the induction heating head assembly 14 may be attached to a fixedstructure and a robotic system (not shown) may be used to move theworkpiece 16 relative to the induction heating head assembly 14. Forexample, when the workpiece 16 is a flat plate, the workpiece 16 may betranslated in a plane generally parallel to and proximate the inductionheating head assembly 14, or when the workpiece 16 is a pipe, theworkpiece 16 may be rotated such that an outer circumference remainsproximate the induction heating head assembly 14.

FIG. 4 is a bottom perspective view of the induction heating headassembly 14 of FIG. 3. As illustrated in FIG. 4, in certain embodiments,a plurality of wheels 74 are coupled to the main housing 26 of theinduction heating head assembly 14. Although illustrated in FIG. 4 asincluding four wheels 74, in other embodiments, the induction heatinghead assembly 14 may include different numbers of wheels 74, such astwo, three, five, six, and so forth. The wheels 74 are sized andpositioned with respect to the induction heating head assembly 14 toprovide a relatively consistent distance of the induction heating headassembly 14 with respect to the workpiece 16 being heated. The wheels 74may be sized to accommodate a wide range of material diameters (e.g.,when the workpiece 16 is pipe) including small to large outsidediameters, as well as flat surfaces. Furthermore, certain embodimentsmay include a plurality of mounting hole locations in the main housing26 corresponding to each wheel 74 such that different wheel positionsand workpiece diameters may be accommodated. Indeed, in certainembodiments, wheel heights, wheel diameters, wheel placement, and soforth, may all be adjustable. In addition, in certain embodiments,spacers may be disposed on the bottom of the main housing 26 of theinduction heating head assembly 14 that do not rotate like the wheels 74but rather slide across the surface of the workpiece 16, therebyproviding further stability of the distance between the inductionheating head assembly 14 and the workpiece 16.

Although illustrated in the figures and described herein as includingwheels 74 that facilitate the induction heating head assembly 14 rollingacross the workpiece 16, in other embodiments where the inductionheating head assembly 14 moves with respect to the workpiece 16 whileremaining in contact with the workpiece 16, other contacting features(i.e., instead of the wheels 74) may be used to maintain contact withthe workpiece 16 while the induction heating head assembly 14 moves withrespect to the workpiece 16. For example, in certain embodiments, theinduction heating head assembly 14 may include a continuous track that,for example, continuously moves around two or more wheels. Furthermore,again, in yet other embodiments, the induction heating head assembly 14may move relative to the workpiece 16 without contacting the workpiece16, the workpiece 16 may move relative to the induction heating headassembly 14 without contacting the induction heating head assembly 14,or both the induction heating head assembly 14 and the workpiece 16 maymove relative to each other without contacting each other.

As illustrated in FIG. 4, in certain embodiments, the wheels 74 aredisposed between the main housing 26 of the induction heating headassembly 14 and a bracket 76 that is attached to a lateral outer wall ofthe main housing 26 (e.g., on the second lateral side 44 of theinduction heating head assembly 14). Although not fully illustrated inFIG. 4, in certain embodiments, a second bracket 76 may be attached toan opposite lateral wall of the main housing 26 of the induction heatinghead assembly 14 (e.g., on the first lateral side 42 of the inductionheating head assembly 14). As described in greater detail herein, incertain embodiments, the travel sensor assembly 30 may be held in placewith respect to the main housing 26 of the induction heating headassembly 14 via the bracket(s) 76.

Furthermore, in certain embodiments, the travel sensor assembly 30 maybe removably attached to the bracket(s) 76 such that the travel sensorassembly 30 may be selectively disposed on either lateral side 42, 44 ofthe induction heating head assembly 14, thereby enabling a broader rangeof induction heating applications and orientations. More specifically,as illustrated in FIG. 4, in certain embodiments, the travel sensorassembly 30 includes a mating bracket 78 that is configured to mate withthe bracket(s) 76 that are attached to the main housing 26 of theinduction heating head assembly 14. Once aligned with each other, thebrackets 76, 78 are held in place with respect to each other via anadjustable connection mechanism 80, such as the knob assembly 82illustrated in FIG. 4. In certain embodiments, the adjustable connectionmechanism 80 includes a biasing member, such as a spring, against whichthe knob (or other connecting means) acts to hold the bracket 78 againstthe mating bracket 76, thereby holding the travel sensor assembly 30 inplace with respect to the main housing 26 of the induction heating headassembly 14. FIG. 5 is an exploded perspective view of the inductionheating head assembly 14, illustrating the brackets 76, 78 and theadjustable connection mechanism 80 when the brackets 76, 78 are notattached to each other via the adjustable connection mechanism 80.

In certain embodiments, the travel sensor assembly 30 may not only beremovable from the main housing 26 of the induction heating headassembly 14, as described with respect to FIGS. 4 and 5, but ahorizontal position of the travel sensor assembly 30 along thehorizontal axis 36 with respect to the main housing 26 of the inductionheating head assembly 14 (when attached to either lateral side 42, 44 ofthe induction heating head assembly 14) may be adjusted, as illustratedby arrow 83. More specifically, the brackets 76, 78 may collectivelyconstitute a rail system upon which the travel sensor assembly 30 mayslide along the horizontal axis 36 to adjust the horizontal position ofthe travel sensor assembly 30 along the horizontal axis 36 with respectto the main housing 26 of the induction heating head assembly 14. Oncein a desired horizontal position, the adjustable connection mechanism 80may ensure that the travel sensor assembly 30 remains in a fixedposition with respect to the main housing 26 of the induction heatinghead assembly 14.

It should be noted that while illustrated in the figures and describedherein as being removably detachable from the induction heating headassembly 14, in other embodiments, the travel sensor assembly 30 mayinstead be used completely separate from (i.e., not mounted to) theinduction heating head assembly 14 during operation of the travel sensorassembly 30 and the induction heating head assembly 14. For example, inone non-limiting example, the travel sensor assembly 30 and theinduction heating head assembly 14 may be attached to separatestructures with the travel sensor assembly 30 detecting the relativeposition and/or movement (including direction of movement) of theinduction heating head assembly 14 with respect to the workpiece 16 andthe induction heating head assembly 14 separately providing inductionheat to the workpiece 16.

Returning now to FIG. 4, as illustrated, the induction heating headassembly 14 also includes an adjustable handle mounting assembly 84(e.g., a mounting bracket in the illustrated embodiment) to which thehandle 72 is attached. In certain embodiments, the adjustable handlemounting assembly 84 is adjustable such that an orientation of thehandle 72 with respect to the main housing 26 and, in turn, theinduction heating head assembly 14 may be adjusted. For example, FIG. 4illustrates the adjustable handle mounting assembly 84 and the attachedhandle 72 in a first orientation whereby a longitudinal axis 86 of thehandle 72 is aligned generally parallel to the horizontal axis 36 of theinduction heating head assembly 14. In contrast, FIG. 6 illustrates theadjustable handle mounting assembly 84 and the attached handle 72 in asecond orientation whereby the longitudinal axis 86 of the handle 72 isat an angle with respect to the vertical axis 32 and the horizontal axis36 of the induction heating head assembly 14.

Although the adjustable handle mounting assembly 84 is illustrated inFIGS. 4 and 6 as facilitating different orientations of the handle 72 ina plane generally defined by the vertical axis 32 and the horizontalaxis 36 of the induction heating head assembly 14, it will beappreciated that in other embodiments, the adjustable handle mountingassembly 84 may enable adjustment of the orientation of the handle 72with respect to all three axes 32, 34, 36 of the induction heating headassembly 14. As a non-limiting example, although illustrated in FIGS. 4and 6 as including a mounting bracket with opposing bracket portionsconnected by a common hinged edge, other embodiments of the adjustablehandle mounting assembly 84 may include a ball and socket configuration(e.g., with either the ball being attached to the handle 72 and thesocket being attached to the main housing 26 of the induction heatinghead assembly 14, or vice versa) that facilitates adjustment of theorientation of the handle 72 with respect to all three axes 32, 34, 36of the induction heating head assembly 14.

As also illustrated in FIG. 6, in certain embodiments, the inductionheating head assembly 14 may include one or more crossbars 88 thatextend from opposite lateral sides 42, 44 of the main housing 26. Thecrossbars 88 may serve several functions, for example, facilitatingmanual manipulation of movement of the induction heating head assembly14 by a person either during operation of the induction heating headassembly 14 or when the induction heating head assembly 14 is beingmanually transported from one location to another.

FIG. 7A is a partial cutaway perspective view of the main housing 26 andthe cable strain relief cover 24 of an exemplary embodiment of theinduction heating head assembly 14 with certain components removed tofacilitate illustration of certain features. As illustrated in FIG. 7A,an induction head assembly 90 includes an induction head 92, a thermalinsulation layer 94, and an insulation and wear surface 96 thatgenerally serves as the bottom side of the main housing 26 of theinduction heating head assembly 14. As illustrated, the induction head92 is disposed within an interior volume defined between the thermalinsulation layer 94, which is disposed adjacent and internal to theinsulation and wear surface 96, and an interior partition 98 of the mainhousing 26 to which the cable strain relief cover 24 is attached. Thethermal insulation layer 94 may be comprised of any suitable insulatingmaterial. The insulation and wear surface 96 may be comprised of mica,ceramic, or any other insulating material that wears.

In certain embodiments, the insulation and wear surface 96 may providesufficient thermal insulation that the separate thermal insulation layer94 may be omitted. Conversely, in certain embodiments, the insulationand wear surface 96 may not be used at all. In such an embodiment, thethermal insulation layer 94 may be the externally facing surface of theinduction heating head assembly 14. In other embodiments, the insulationand wear surface 96 may serve as only a wear surface that is comprisedof a material that provides relatively less thermal insulation, withmost of the thermal insulation be provided by the thermal insulationlayer 94. In certain embodiments, multiple thermal insulation layers 94may be used. In general, the insulation and wear surface 96 protects thethermal insulation layer(s) 94 and the induction coil of the inductionhead 92 from abrasion and possible thermal damage. In particular, theinsulation and wear surface 96 is an externally facing surface thatisolates the induction coil of the induction head, as well as thethermal insulation layer(s) 94, from an exterior of the inductionheating head assembly 14. A wear surface such as the insulation and wearsurface 96, as described herein, is a surface designed to protect a coilof the induction head assembly 90 from incidental contact with theworkpiece 16, without unduly wearing the surface, by being the point ofcontact when inadvertent contact with the workpiece 16 is made. Incertain embodiments, more than one insulation and wear surface 96 may beincluded, such as for heating two surfaces of a corner.

In certain embodiments, the induction head assembly 90 includes anadditional wear surface to prevent unwanted contact with the inductioncoil. For example, FIG. 7B is a perspective view of the inductionheating head assembly 14 with the thermal insulation layer(s) 94 and theinsulation and wear surface 96 removed for illustration purposes. Inaddition, FIG. 7C is a cutaway side view of the induction heating headassembly 14. FIGS. 7B and 7C illustrate a ceramic spacer 99 that isdisposed between the one or more thermal insulation layer(s) 94 and theconductive coil 108 of the induction head 92 of the induction headassembly 90. As illustrated in FIG. 7B, the ceramic spacer 99 is shapedsimilarly to the conductive coil 108 (e.g., Q-shaped, having a generallycircular portion with a tongue 101 extending radially outward from thecircular portion) to generally align with the conductive coil 108 andits connections 120 (illustrated in FIGS. 8, 9, and 10A through 10C) toprovide added protection for the conductive coil 108 and its connections120.

FIG. 8 is an exploded view of an exemplary embodiment of the inductionhead 92, which includes an outer housing 100, a first layer of thermallyconductive potting compound 102, a flux concentrator 104, a second layerof thermally conductive potting compound 106, and the conductive coil108. The coil 108 may be comprised of copper, aluminum, or anotherrelatively conductive material. In certain embodiments, the outerhousing 100 may be comprised of aluminum, although other materials maybe used. In certain embodiments, the layers of potting compounds 102,106 may comprise a thermally conductive material such as silicone. Incertain embodiments, the thermally conductive potting compounds 102, 106may be any other media or devices that spatially secure the coil 108with respect to the flux concentrator 104. In other words, the thermallyconductive potting compounds help hold the coil 108 in a fixed positionwith respect to the flux concentrator 104. In certain embodiments, theflux concentrator 104 may be comprised of ferrite or a Fluxtrol®material, although other materials may be used. In general, the fluxconcentrator 104 redirects the magnetic field from the top and sides ofthe coil 108 toward the wear surface of the induction head 92 (i.e., theside of the induction head 92 that abuts the thermal insulation layer(s)94 of the induction head assembly 90). In other words, the fluxconcentrator 104 concentrates a flux toward the insulation and wearsurface 96. During operation of the induction heating head assembly 14,the coil 108 is held in proximity to the workpiece 16 being heated. Inembodiments where two insulation and wear surfaces 96 are included, thecoil 108 may be bent to be near both surfaces. Alternatively, in certainembodiments, parallel coils 108 may be used with two flux concentrators104.

FIG. 9 is a perspective view of the conductive coil 108 of the inductionhead 92 of FIG. 8. As illustrated, in certain embodiments, the coil 108is wound in a stacked pancake spiral pattern having at least two layers110 with at least four turns 112 in each layer 110. However, in certainembodiments, fewer turns 112 (e.g., at least two turns 112) per layer110 may be used such that less power is consumed by the coil 108. Thestacked pancake spiral pattern of the coil 108, as described herein,means that the coil 108 is wound in multiple spirals (i.e., layers 110)with each spiral in a plane (e.g., generally perpendicular to a centralaxis 114 of the coil 108) that is different from each other. Forexample, the two layers 110 of turns 112 may each be arranged ingenerally parallel respective planes with the layers 110 of turns 112abutting each other. The number of turns 112 in a spiral pattern, asdescribed herein, is the number of times the coil 108 crosses a givenline 116 extending radially outward in one direction from the centralaxis 114 of the spiral. The spiral pattern, as described herein, refersto the coil 108 having a pattern wound about the central axis 114,wherein a path 118 along the turns 112 taken from the outermost turn 112to the innermost turn 112 results in a distance d_(turn) from the path118 to the central axis 114 decreasing on average. In certainembodiments, the spiral pattern of the coil 108 includes patterns wherethere are local variations from the decreasing distance d_(turn), suchas square spirals, oval spirals, distorted spirals, and so forth, asopposed to the generally constantly decreasing distance d_(turn) of thegenerally circular spirals of the embodiment illustrated in FIG. 9.

Certain embodiments provide for the coil 108 having an outer diameterd_(outer) that is approximately 4 inches, approximately 6 inches, orapproximately 8 inches. However, coils 108 having other outer diametersd_(outer) may be used. For example, in certain embodiments, even largercoils 108 may be used. The multi-turn design of the coil 108 helpsdistribute heat more evenly across the heat zone applied to theworkpiece 16 and keeps the design of the coil 108 relatively compact. Inparticular, including multiple layers 110 in a stacked relationshipkeeps the footprint of the coil 108 and, in turn, the induction headassembly 90 relatively compact. As described herein, in certainembodiments, the turns 112 of the coil 108 may be a hollow tube toenable a coolant to flow through the turns 112, thereby providinginternal cooling of the turns 112.

Certain embodiments provide for a single pancake spiral pattern coil 108as opposed to the multiple layer embodiment illustrated in FIGS. 8 and9. Other embodiments provide for other patterns and sizes of the coil108, and for using conductive materials other than copper (e.g.,aluminum) for the coil 108. For example, non-limiting examples of otherembodiments include a coil 108 with a single layer spiral (i.e., notstacked), an eight turn 112 double-stacked coil 108, a coil 108 cooledby fluid in contact with (rather than through a hollow interior of theturns 112) the coil 108, such as fluid flowing within spaces in thepotting compounds 102, 106, as well as other patterns, sizes, shapes anddesigns.

FIGS. 10A through 10C illustrate another embodiment of the coil 108. Thecoil 108 illustrated in FIG. 10A is a two-layer stacked spiral with fourturns 112 per layer 110. However, the connections 120 at the oppositeends of the coil 108 that are configured to connect to the cable strainrelief cover 24 are arranged differently than the connections 120 of theembodiment illustrated in FIGS. 8 and 9. FIGS. 10B and 10C are bottomand top perspective views of the coil 108 of FIG. 10A with the fluxconcentrator 104 disposed about the coil 108.

In general, the number and size of the layers 110 and the turns 112 ofthe coil 108 are selected to tune the coil 108 to the particular powersource 12 that provides power to the coil 108. As such, as illustratedin FIG. 7A, in certain embodiments, the induction head assembly 90 maybe removable and replaceable from the interior volume defined betweenthe thermal insulation layer 94, which is disposed adjacent and internalto the insulation and wear surface 96, and an interior partition 98 ofthe main housing 26 of the induction heating head assembly 14. In otherwords, to ensure that the coil 108 is properly tuned to the power source12 providing power to it, the particular induction head assembly 90 usedin the induction heating head assembly 14 may be changed as needed.Alternatively, the entire induction heating head assembly 14, whichincludes the particular induction head assembly 90, may be matched tothe power source 12 being used to provide power to the induction heatinghead assembly 14. When choosing the coil design, the diameter (e.g.,when the workpiece 16 is a pipe), material type, thickness, and soforth, of the workpiece 16 to be heated should also be considered.

Because the coil 108 is tuned to the power source 12, the inductionheating system 10 illustrated in FIG. 1 does not require a transformerbetween the induction heating head assembly 14 and the power source 12that steps down or steps up the voltage provided by the power source 12.Rather, the induction heating head assembly 14 can connect directly tothe power source 12 without the additional cost, size, and weight thatwould result from using a transformer. Furthermore, the voltage appliedto the coil 108 is not less than the voltage from the output circuitry52 of the power source 12.

FIG. 11 is a side view of the main housing 26 and the temperature sensorassembly 28 of an embodiment of the induction heating head assembly 14,illustrating how the temperature sensor assembly 28 attaches to the mainhousing 26. As illustrated, in certain embodiments, the temperaturesensor assembly 28 includes a first bracket 122 and a smaller secondbracket 124 that may be coupled to each other via an adjustableconnection mechanism 126, such as the knob assembly 128 illustrated inFIG. 11, which is substantially similar to the adjustable connectionmechanism 80 and the knob assembly 82 of the travel sensor assembly 30described herein with respect to FIGS. 4 and 5. In certain embodiments,the adjustable connection mechanism 126 includes a biasing member, suchas a spring, against which the knob (or other connecting means) acts tohold the smaller bracket 124 in a fixed position with respect to thelarger bracket 122, thereby holding the temperature sensor assembly 28in place with respect to the main housing 26 of the induction heatinghead assembly 14.

FIG. 12 is a zoomed in perspective view of the first and second brackets122, 124 of the temperature sensor assembly 28, the adjustableconnection mechanism 126 of the temperature sensor assembly 28, and themain housing 26 of the induction heating head assembly 14, illustratingin more detail how the first and second brackets 122, 124 of thetemperature sensor assembly 28 may attach to the main housing 26. Asillustrated, the main housing 26 includes first and second matingbrackets 130, 132 that are configured to mate with the first and secondbrackets 122, 124 of the temperature sensor assembly 28. In particular,in certain embodiments, the first mating bracket 130 of the main housing26 includes a first mating lip 134 configured to mate with a lip 136 ofthe first bracket 122 of the temperature sensor assembly 28, and thesecond mating bracket 132 of the main housing 26 includes a secondmating lip 138 configured to mate with a lip 140 of the second bracket124 of the temperature sensor assembly 28.

It will be appreciated that once the lip 136 of the first bracket 122 ofthe temperature sensor assembly 28 is brought into position with respectto the mating lip 134 of the first mating bracket 130 of the mainhousing 26, thereby engaging the first bracket 122 of the temperaturesensor assembly 28 with the first mating bracket 130 of the main housing26, and the lip 140 of the second bracket 124 of the temperature sensorassembly 28 is brought into position with respect to the mating lip 138of the second mating bracket 132 of the main housing 26, therebyengaging the second bracket 124 of the temperature sensor assembly 28with the second mating bracket 132 of the main housing 26, theadjustable connection mechanism 126 of the temperature sensor assembly28 may be used to secure the first and second brackets 122, 124 to eachother, thereby holding the temperature sensor assembly 28 in a fixedposition with respect to the main housing. Furthermore, it will beappreciated that first and second brackets 122, 124 and the adjustableconnection mechanism 126 enable the temperature sensor assembly 28 to beentirely removable from the main housing 26, which enables maintenance,repair, and replacement of the temperature sensor assembly 28. Forexample, in certain situations, a different type of temperature sensorassembly 28 (e.g., having temperature sensors better suited fordetecting temperatures on certain workpiece materials, etc.) may beinterchanged for the temperature sensor assembly 28 that is currentlyattached to the main housing 26 of the induction heating head assembly14. Moreover, in certain embodiments, the temperature sensor assembly 28may be completely separate from (i.e., not mounted to) the inductionheating head assembly 14 during operation of the temperature sensorassembly 28 and the induction heating head assembly 14.

FIG. 13 is an exploded perspective view of the first and second brackets122, 124 of the temperature sensor assembly 28, the adjustableconnection mechanism 126 of the temperature sensor assembly 28, and themain housing 26 of the induction heating head assembly 14, illustratingthe brackets 122, 124, 130, 132 and the adjustable connection mechanism126 when the brackets 122, 124, 130, 132 are not attached to each othervia the adjustable connection mechanism 126. It will be appreciated thatthe adjustable nature of the brackets 122, 124, 130, 132 and theadjustable connection mechanism 126 enables the temperature sensorassembly 28 to be selectively moved from side-to-side of the mainhousing 26 of the induction heating head assembly 14.

For example, FIG. 14 is front view of an embodiment of the temperaturesensor assembly 28 and the main housing 26 of the induction heating headassembly 14, illustrating how a horizontal position of the temperaturesensor assembly 28 with respect to the main housing 26 along thehorizontal axis 34 is adjustable. As illustrated by arrow 142, the fixedposition of the temperature sensor assembly 28 with respect to thelateral sides 42, 44 of the main housing 26 may be adjusted by, forexample, loosening the knob 128 of the adjustable connection mechanism126, adjusting the positioning of the first and second brackets 122, 124of the temperature sensor assembly 28 (e.g., along the horizontal axis34 of the induction heating head assembly 14) with respect to the fixedfirst and second mating brackets 130, 132 of the main housing 26, andre-tightening the knob 128 of the adjustable connection mechanism 126.In other words, the brackets 122, 124, 130, 132 may collectivelyconstitute a rail system along which the temperature sensor assembly 28may slide along the horizontal axis 34 of the induction heating headassembly 14. In certain embodiments, the rail system enables more thanone temperature sensor assembly 28 to be mounted to the inductionheating head assembly 14, for example, such that a first temperaturesensor assembly 28 may be positioned on a first lateral side of a weldbeing performed and a second temperature sensor assembly 28 may bepositioned on a second lateral side of the weld being performed.

Returning now to FIG. 11, as illustrated, in certain embodiments, thetemperature sensor assembly 28 includes a generally cylindrical shapedbody 144 within which a temperature sensor is disposed, as describedherein. As illustrated, in certain embodiments, the body 144 isgenerally parallel with the first bracket 122 of the temperature sensorassembly 28. In general, the body 144 of the temperature sensor assembly28 is oriented such that a lower air cup 146 disposed at an axial end ofthe cylindrical body 144 is pointed, along a central axis 148 of thebody 144, toward an area of the workpiece 16 at which induction heatingis occurring. In certain embodiments, the position of the lower air cup146 of the body 144 with respect to the main housing 26 of the inductionheating head assembly 14 remains fixed. However, in other embodiments,an inner cylinder 150 of the temperature sensor assembly 28, whichincludes a temperature sensor, may be configured to translate withrespect to the central axis 148 of the body 144 such that the innercylinder 150 may be moved closer to or farther away from the workpiece16 along the central axis 148, as illustrated by arrow 152. For example,in certain embodiments, the inner cylinder 150 may be moved axiallyalong the central axis 148 through first and second bumpers 154, 156,which are fixed to the first bracket 122 and provide protection of theinner cylinder 150 from unwanted contact during movement of theinduction heating head assembly 14. As such, a height distance (i.e.,vertical position) of the inner cylinder 150 along the vertical axis 32of the induction heating head assembly 14 is adjustable, and an offsetdistance of the inner cylinder 150 along the horizontal axis 36 is alsoadjustable, thereby modifying the overall distance of the inner cylinder150, and the components disposed within it (e.g., a temperature sensorand associated components), from the workpiece 16. Adjusting theposition of the inner cylinder 150 along the central axis 148 in thismanner enables tuning of the operation of the temperature sensor that isdisposed in the inner cylinder 150. For example, if the sensitivity ofthe detected temperature needs to be increased, the inner cylinder 150may be moved closer to the workpiece 16 along the central axis 148.

As illustrated in FIG. 11, in certain embodiments, the central axis 148(e.g., along a path of detection) of the body 144 of the temperaturesensor assembly 28 may be disposed at an angle α_(temp) with respect tothe horizontal axis 36. The illustrated embodiment has the body 144 ofthe temperature sensor assembly 28 disposed at an angle α_(temp) ofapproximately 50°. However, it will be appreciated that the temperaturesensor assembly 28 may be configured to utilize other angles α_(temp)such as approximately 30°, approximately 35°, approximately 40°,approximately 45°, approximately 55°, approximately 60°, and so forth.Furthermore, in certain embodiments, the temperature sensor assembly 28may be configured to enable the angle α_(temp) at which the central axis148 of the body 144 is disposed to be adjusted by a user.

For example, as illustrated in FIG. 12, the design of the lips 136, 140of the first and second brackets 122, 124 of the temperature sensorassembly 28 and the mating lips 134, 138 of the first and second matingbrackets 130, 132 of the main housing 26 may enable an angle between thefirst bracket 122 of the temperature sensor assembly 28 and the matingfirst bracket 130 of the main housing 26 to be adjusted, and an anglebetween the second bracket 124 of the temperature sensor assembly 28 andthe mating second bracket 132 of the main housing 26 to also be adjustedwhile the adjustable connection mechanism 126 is not engaged with thefirst and second brackets 122, 124 of the temperature sensor assembly28. Once the angular orientations between the first bracket 122 of thetemperature sensor assembly 28 and the mating first bracket 130 of themain housing 26 and between the second bracket 124 of the temperaturesensor assembly 28 and the mating second bracket 132 of the main housing26 are re-adjusted, the adjustable connection mechanism 126 mayre-engage the first and second brackets 122, 124 of the temperaturesensor assembly 28.

However, in certain embodiments, to facilitate the re-adjusted angularorientations between the first bracket 122 of the temperature sensorassembly 28 and the mating first bracket 130 of the main housing 26 andbetween the second bracket 124 of the temperature sensor assembly 28 andthe mating second bracket 132 of the main housing 26, the adjustableconnection mechanism 126 may re-engage with different mating features inthe first bracket 122 and/or the second bracket 124 of the temperaturesensor assembly 28. For example, as a non-limiting example, in certainembodiments, the knob 128 of the adjustable connection mechanism 126 mayengage with a sole mating hole in the second bracket 124 of thetemperature sensor assembly 28, but mate with one of a plurality ofdifferent mating holes in the first bracket 122 of the temperaturesensor assembly 28 at a plurality of different locations 158, as shownin the embodiment of the first bracket 122 illustrated in FIG. 15. Theplurality of hole locations 158 in the first bracket 122 facilitatedifferent angular orientations between the first bracket 122 of thetemperature sensor assembly 28 and the mating first bracket 130 of themain housing 26 and between the second bracket 124 of the temperaturesensor assembly 28 and the mating second bracket 132 of the main housing26.

FIG. 16 is a perspective view of an embodiment of the temperature sensorassembly 28. As illustrated, in certain embodiments, the second bracket124 of the temperature sensor assembly 28 includes a bracket section 160that is configured to support a connector assembly 162 that includes theconnector 68 that connects the cable 18 from the power source 12 to thetemperature sensor assembly 28. As illustrated, in certain embodiments,the connector assembly 162 includes a flexible control cable 164 thatcouples to the inner cylinder 150 of the body 144 of the temperaturesensor assembly 28 at an axial end opposite the lower air cup 146 thatis at an axial end closest to the workpiece 16 during operation. Ingeneral, the flexible control cable 164 is used to transmit controlsignals received from the power source 12 to the working components(e.g., a temperature sensor and related components) of the temperaturesensor assembly 28 residing within the inner cylinder 150, and totransmit feedback signals (e.g., relating to temperature data) from theworking components of the temperature sensor assembly 28 residing withinthe inner cylinder 150 back to the power source 12. As will beappreciated, the flexible nature of the control cable 164 enables theinner cylinder 150 of the body 144 of the temperature sensor assembly 28to be translated toward or away from the workpiece 16 without placingstrain on the control cable 164, the connector assembly 162, the innercylinder 150, or any other components of the temperature sensor assembly28. As also illustrated in FIG. 16, in certain embodiments, the secondbracket 124 of the temperature sensor assembly 28 also includes abracket section 166 that generally protects the flexible control cable164 from unwanted contact near the point of connection with the innercylinder 150.

FIG. 17A is a partial cutaway side view of the temperature sensorassembly 28. The body 144 of the temperature sensor assembly 28 includesthe first and second bumpers 154, 156 that are configured to hold thebody 144 in place with respect to the first bracket 122 of thetemperature sensor assembly 28 by attaching to first and second bracketsections 168, 170, respectively, that extend generally perpendicularlyfrom a main surface 172 of the first bracket 122, and also protect theinner cylinder 150 from undesired contact during transport and/oroperation. As described herein, in certain embodiments, the componentsof the body 144 (e.g., including the inner cylinder 150, the first andsecond bumpers 154, 156, the lower air cup 146, and so forth) may betranslated along the central axis 148 of the body 144 such that thecomponents of the body 144 are brought closer to or farther away fromthe workpiece 16.

As illustrated in FIG. 17A, in certain embodiments, a temperature sensor174 is disposed within the inner cylinder 150 near a distal axial end(e.g., an axial end nearer the workpiece 16 during operation) of theinner cylinder 150. In certain embodiments, the temperature sensor 174is an infrared (IR) sensor that does not contact the workpiece 16.However, in other embodiments, instead of being non-contacting, thetemperature sensor 174 may contact the workpiece 16 during detection ofthe temperature of the workpiece 16. In certain embodiments, asillustrated by arrow 176, the temperature sensor 174 may be rotated(e.g., at least 180 degrees, or even a full 360 degrees) about thecentral axis 148 such that the temperature sensor 174 can focusdetection of heat from the workpiece 16 in different ways.

In certain embodiments, more than one temperature sensor 174 may be usedto more accurately read temperatures across a spectrum of emissivitylevels because material surface preparation can result in a variety ofsurface emissivities from part to part or within a given part itself.For example, a first temperature sensor 174 may be used when a surfaceemissivity of the workpiece 16 falls within a first range, while asecond temperature sensor 174 may be used when the surface emissivity ofthe workpiece 16 falls within a second range. As such, the firsttemperature sensor 174 may be better suited to detect temperatures fromcertain types of workpiece materials while the second temperature sensor174 may be better suited to detect temperatures from other types ofworkpiece materials. In some situations, the first and secondtemperature sensors 174 are focused on the same location of theworkpiece 16 being heated. However, in other situations, the first andsecond temperature sensors 174 may be focused on slightly or completelydifferent locations. For example, in certain embodiments, thetemperature sensor(s) 174 may have a field of vision “window” directlyin line with a weld being performed on the workpiece 16. The pluralityof temperature sensors 174 may either be disposed within the body 144 ofthe temperature sensor assembly 28 simultaneously (and, for example, beselectively used at any given time) or may be interchangeably removablefrom the temperature sensor assembly 28 for different operatingconditions (e.g., different surface emissivities, different expectedtemperature ranges, and so forth).

Using a plurality of temperature sensors 174 enables the temperaturesensor assembly 28 to detect temperatures in a plurality of wavelengthranges. For example, in certain embodiments, the temperature sensor 174of the temperature sensor assembly 28 may be capable of using multiplewavelengths (or a range of wavelengths) to detect a temperature of theworkpiece 16. Alternatively, in other embodiments, the temperaturesensor assembly 28 may include multiple different temperature sensors174, each capable of detecting a temperature of the workpiece 16 atdifferent wavelengths (or ranges of wavelengths). In such an embodiment,the different temperature sensors 174 may be selectively used by a userof the temperature sensor assembly 28. For example, in certainembodiments, the temperature sensor assembly 28 may allow a user tomanually select which of the different temperature sensors 174 arecurrently being used (e.g., by toggling a switch on an external surfaceof the inner cylinder 150 of the temperature sensor assembly 28, byrotating the inner cylinder 150 of the temperature sensor assembly 28about its central axis 148 (e.g., along a path of detection of thetemperature sensor assembly 28) such that a desired one of thetemperature sensors 174 is optically aligned to detect the temperatureof the workpiece 16, and so forth).

In certain embodiments, the temperature sensor(s) 174 of the temperaturesensor assembly 28 are configured to detect the temperature of theworkpiece 16 at a plurality of wavelengths relating to a plurality ofsurface emissivities, and to transmit a feedback signal relating to thedetected temperature of the workpiece 16 to the controller circuitry 50without compensation for the particular surface emissivity of theworkpiece 16. In other words, the temperature sensor(s) 174 of thetemperature sensor assembly 28 are specifically selected to be optimallyused with certain workpiece materials that have certain expected surfaceemissitivies such that no additional processing of the detectedtemperature is required by the temperature sensor assembly 28 or thecontroller circuitry 50. For example, neither the temperature sensorassembly 28 nor the controller circuitry 50 needs to compensate for thetype of workpiece material being heated (e.g., via a setting input by auser). In such embodiments, certain temperature sensor assemblies 28will be known to work with certain workpiece materials withoutadditional calibration, setup, input of workpiece properties, etc. Incertain embodiments, the temperature sensor(s) 174 of the temperaturesensor assembly 28 may be configured to detect temperatures at aplurality of different wavelengths less than approximately 8.0micrometers, within a range of approximately 1.0 micrometers andapproximately 5.0 micrometers, within a range of approximately 2.0micrometers and approximately 2.4 micrometers, and so forth. Thesewavelength ranges are merely exemplary and not intended to be limiting.Other wavelength ranges may be used for certain embodiments of thetemperature sensor assembly 28.

FIGS. 17B and 17C are a perspective view and an exploded perspectiveview, respectively, of the temperature sensor assembly 28. Asillustrated in FIGS. 17B and 17C, in certain embodiments, a protectivewindow 178 may be disposed at an axial end of the lower air cup 146along the central axis 148 (e.g., along a path of detection) of thetemperature sensor assembly 28 and, in certain embodiments, may be heldin place at the axial end of the lower air cup 146 using a retainingring 177 that may, for example, be configured to attach to (e.g., screwonto, lock into place using a twist locking mechanism, and so forth) amating attachment means 179 (e.g., threading, a mating twist lockingmechanism, and so forth) disposed at the axial end of the lower air cup146. In general, the protective window 178 may protect a lens of thetemperature sensor 174 during operation of the induction heating headassembly 14. More specifically, the protective window 178 may protectthe lens of the temperature sensor 174 from spatter from a weld beingperformed on the workpiece 16, from other debris that may be sucked orblown into the interior of the lower air cup 146 of the body 144, and soforth. In certain embodiments, the protective window 178 may becomprised of an IR-transparent material, such as quartz.

Air received by the temperature sensor assembly 28 via the air cableconnector 70 is delivered through a port 171 of an upper air cup 173 viaan air cable 175. In certain embodiments, the upper air cup 173 threadsonto the inner cylinder 150, and retains the body 144 to the firstbracket 122. In addition, in certain embodiments, the lower air cup 146threads into the upper air cup 173 and, as such, is removable from theupper air cup 173 to facilitate access to the lens of the temperaturesensor 174 if it needs cleaning. In certain embodiments, the air thatflows through the air cup 146, 173 (which may collectively be referredto as “the air cup” when assembled together) escapes through one or moreopenings 181 that extend radially through an outer wall of the lower aircup 146. In other embodiments, the air may escape axially through theprotective window 178 via openings (not shown) that may extend axiallythrough the protective window 178. As such, positive pressure isprovided from within the temperature sensor assembly 28 to clear debris,clean internal components, and so forth. In other embodiments where aprotective window 178 is not used, the openings 181 may not be used inthe lower air cup 146, and the air may instead escape through the openaxial end of the lower air cup 146.

Although certain embodiments include one temperature sensor assembly 28attached to a first (i.e., front) side 38 of the induction heating headassembly 14, in other embodiments, more than one temperature sensorassembly 28 may be attached to the induction heating head assembly 14.For example, FIG. 18 is a side view of an embodiment of the inductionheating head assembly 14 having a first temperature sensor assembly 28attached to a first (i.e., front) side 38 of the induction heating headassembly 14 and a second temperature sensor assembly 28 attached to asecond (i.e., back) side 40 of the induction heating head assembly 14.For example, in certain embodiments, instead of including the adjustablehandle mounting assembly 84 attached on the back side 40 of the mainhousing 26, the induction heating head assembly 14 may include first andsecond mating brackets 130, 132 attached on the back side 40 of the mainhousing 26 that are substantially similar to the first and second matingbrackets 130, 132 attached to the front side 38 of the main housing 26(for example, as illustrated in FIG. 12). In such an embodiment, atemperature sensor assembly 28 may be coupled to the main housing 26 oneither the front side 38 or the back side of the main housing 26, or afirst temperature sensor assembly 28 may be coupled to the main housing26 on the front side 38 of the main housing 26 and a second temperaturesensor assembly 28 may be coupled to the main housing 26 on the backside 40 of the main housing 26. In other embodiments, the adjustablehandle mounting assembly 84 may be detachable from the back side 40 ofthe main housing 26, and first and second mating brackets 130, 132 maybe attached to the back side 40 of the main housing 26 to replace theadjustable handle mounting assembly 84. In such an embodiment, the backside 40 of the main housing 26 would include appropriate features forselectively attaching either the adjustable handle mounting assembly 84or the first and second mating brackets 130, 132 to the back side 40 ofthe main housing 26. In certain embodiments where the adjustable handlemounting assembly 84 is removed from the main housing 26, movement ofthe induction heating head assembly 14 may be accomplished by impartingforces on other alternate features of the induction heating headassembly 14, for example, the crossbars 88 of the main housing 26.

In embodiments where the main housing 26 includes first and secondmating brackets 130, 132 on both the front side 38 and the back side 40of the main housing 26, and first and second temperature sensorassemblies 28 are attached to the first and second mating brackets 130,132 on the front side 38 and the back side 40 of the main housing 26,respectively, the first and second temperature sensor assemblies 28enable detection of temperatures from the workpiece 16 both in front of(i.e., leading) and behind (i.e., trailing) the induction heatinggenerated by the induction heating head assembly 14.

It should be noted that while illustrated in the figures and describedherein as being removably detachable from the induction heating headassembly 14, in other embodiments, the temperature sensor assembly 28may instead be used completely separate from (i.e., not mounted to) theinduction heating head assembly 14 during operation of the temperaturesensor assembly 28 and the induction heating head assembly 14. Forexample, in one non-limiting example, the temperature sensor assembly 28and the induction heating head assembly 14 may be attached to separatestructures with the temperature sensor assembly 28 detecting thetemperature of the workpiece 16 and the induction heating head assembly14 separately providing induction heat to the workpiece 16.

FIGS. 19 and 20 are bottom perspective views of the travel sensorassembly 30 and the main housing 26 of the induction heating headassembly 14, illustrating certain features relating to the travel sensorassembly 30. As described above with respect to FIGS. 4 and 5, thebracket 76 of the main housing 26 and the mating bracket 78 of thetravel sensor assembly 30 enable the travel sensor assembly 30 to beremovably detached from the main housing 26, and to enable a horizontalposition of the travel sensor assembly 30 along the horizontal axis 36to be adjusted.

As illustrated, in certain embodiments, the travel sensor assembly 30includes a generally rectangular housing 180 within which components ofthe travel sensor assembly 30 may be disposed. As also illustrated, incertain embodiments, the travel sensor assembly 30 includes a detectionwheel 182 coupled to the housing 180 and configured to rotate withrespect to the housing 180. When in operation, the detection wheel 182rolls along the surface of the workpiece 16 and at least partiallyenables the travel sensor assembly 30 to detect the position and/ormovement (including direction of movement) of the travel sensor-assembly30 and, thus, the induction heating head assembly 14 with respect to theworkpiece 16. As illustrated, in certain embodiments, the detectionwheel 182 includes a removable wear ring 184 that, for example, fitswithin a circumferential groove of the detection wheel 182. The wearring 184 actually interfaces with the workpiece 16 and may be made of arelatively soft material, such as rubber, that may wear over time, butis removable and replaceable as needed. Other embodiments of thedetection wheel 182 may not include a wear ring 184, but rather mayinclude a knurled or smooth detection wheel 182 for directly interfacingwith the workpiece 16.

Furthermore, in certain embodiments, the detection wheel 182 may includea plurality of openings 186 extending through the detection wheel 182.In certain embodiments, these openings 186 facilitate the detection ofthe position and/or movement (including direction of movement) of thetravel sensor-assembly 30 and, thus, the induction heating head assembly14 with respect to the workpiece 16. Although illustrated as includingthree relatively similar circular holes, in other embodiments, theopenings 186 may take different forms, such as a plurality circularholes having differing diameters, a plurality of slots of variousshapes, and so forth. In other embodiments, instead of including aplurality of openings 186 for facilitating detection of the positionand/or movement (including direction of movement) of the travelsensor-assembly 30, in other embodiments, the detection wheel 182 mayinclude a plurality of markings (e.g., on a face of the detection wheel182) for facilitating detection of the position and/or movement(including direction of movement) of the travel sensor assembly 30. Itshould be noted that while illustrated in the figures and describedherein as including the detection wheel 182 as a contacting surface thatis used to determine a position and/or movement (including direction ofmovement) of the travel sensor-assembly 30 with respect to the workpiece16, in other embodiments, other types of contacting travelsensor-assemblies 30 may be used. For example, as a non-limitingexample, one or more brushes that contact the surface of the workpiece16 may facilitate detection of the position and/or movement (includingdirection of movement). In other embodiments, the travel sensor-assembly30 may utilize non-contacting detection means, such as an IR sensor,optical sensor, magnetic sensor, accelerometers and/or gyroscopes, andso forth. Furthermore, in certain embodiments, instead of including aseparate detection wheel 182, the wheels 74 of the induction heatinghead assembly 14 may be used in place of the detection wheel 182 toenable the travel sensor assembly 30 to detect the position and/ormovement (including direction of movement) of the travel sensor-assembly30 with respect to the workpiece 16.

As illustrated in FIG. 20, in certain embodiments, a tensioningmechanism 188 of the travel sensor assembly 30 may be used to adjust avertical position (as well as the force between the travel sensorassembly 30 and the workpiece 16) of the detection wheel 182 of thetravel sensor assembly 30 with respect to the vertical axis 32, asillustrated by arrow 190. FIG. 21 is a zoomed in perspective view of thetensioning mechanism 188 of the travel sensor assembly 30. Asillustrated, in certain embodiments, the tensioning mechanism 188 may beattached to the bracket 78 that is attached to the housing 180 of thetravel sensor assembly 30. More specifically, a bracket section 192 ofthe bracket 78 may extend generally perpendicular to the main section ofthe bracket 78 and include two generally perpendicular bracket sections194, 196. As illustrated, in certain embodiments, a pivot pin 198 mayfit through the bracket section 192 of the bracket 78 and the housing180 of the travel sensor assembly 30 to hold the housing 180 in arelatively fixed position with respect to an axis of the pivot pin 198.An opposite end 200 of the pivot pin 198 is illustrated in FIG. 19. Morespecifically, the pivot pin 198 extends all the way through the housing180 of the travel sensor assembly 30 and through another bracket section202 of the bracket 78 on an opposite side of the housing 180 from thebracket section 192.

Therefore, returning now to FIG. 21, the position of the housing 180 ofthe travel sensor assembly 30 remains fixed with respect to a centralaxis 204 of the pivot pin 198. However, the housing 180 of the travelsensor assembly 30 may be allowed to pivot about the central axis 204 ofthe pivot pin 198 to enable the detection wheel 182 to be moved closerto or farther away from the workpiece 16, as illustrated by arrow 190.More specifically, the side of the housing 180 on which the detectionwheel 182 is disposed may be capable of moving closer to or farther awayfrom the workpiece 16. In general, the bracket sections 192, 194, 196 ofthe bracket 78 of the travel sensor assembly 30 remain fixed in positionwith respect to the bracket 76 of the main housing 26 of the inductionheating head assembly 14, while a bracket section 206 extending from thehousing 180 of the travel sensor assembly 30 may be allowed move up ordown with respect to the bracket 76.

As illustrated, in certain embodiments, the tensioning mechanism 188 mayinclude a cylindrical body 208 having a knob 210 disposed at an axialend of the cylindrical body 208. As the knob 210 is tightened orloosened, a vertical position of an inner shaft 212 that extends throughthe cylindrical body 208 is adjusted, as illustrated by arrow 214. Assuch, a vertical position of a section 216 of the shaft 212, which hasan outer diameter substantially larger than the normal outer diameter ofthe shaft 212, is also adjusted. A biasing member 218, such as a spring,is disposed radially about the shaft 212 between the section 216 of theshaft 212 and the bracket section 206 of the housing 180 of the travelsensor assembly 30. Therefore, as the knob 210 is tightened, the shaft212 moves toward the bracket section 206 of the housing 180 andcounteracts the upward force of the biasing member 218, thereby urgingthe bracket section 206 and, indeed, the housing 180 downward (i.e.,toward the workpiece 16). Accordingly, the detection wheel 182 issimilarly urged toward the workpiece 16. In contrast, as the knob 210 isloosened, the shaft 212 moves away from the bracket section 206 of thehousing 180 and lessens the counteracting forces acting against theupward force of the biasing member 218, thereby urging the bracketsection 206 and, indeed, the housing 180 to release upward (i.e., awayfrom the workpiece 16). Accordingly, the detection wheel 182 issimilarly urged away from the workpiece 16. The spring-loaded nature ofthe biasing member 218 is such that, regardless of the vertical positionof the detection wheel 182 selected using the tensioning mechanism 188of the travel sensor assembly 30, there exists a certain amount of“give” between the detection wheel 182 and the workpiece 16 such thatundesirable jostling, vibrations, and so forth, may be sustained whilemaintaining normal operations.

Any type of sensor may be used in the travel sensor assembly 30 todetect the position, movement, or direction of movement of the detectionwheel 182 and the housing 180 of the travel sensor assembly 30, as wellas the induction heating head assembly 14 as a whole, with respect tothe workpiece 16. For example, as illustrated in FIG. 22, in certainembodiments, the travel sensor assembly 30 may include an optical sensor220, such as an IR sensor, configured to detect the position, movement,or direction of movement of the detection wheel 182 and the housing 180of the travel sensor assembly 30 by detecting light, converting thedetected light into signals, and analyzing the signals. For example, incertain embodiments, the optical sensor 220 may be optically directed,as illustrated by arrow 222, from the housing 180 of the travel sensorassembly 30 toward an area on the detection wheel 182 through which theopenings 186 (see FIG. 19, for example) pass as the detection wheel 182rotates with respect to the housing 180. Accordingly, the light detectedby the optical sensor 220 will change (e.g., pulse) as the detectionwheel 182 rotates. The signals relating to these changes in detectedlight may be analyzed to determine rotational speed of the detectionwheel 182 and, therefore, speed of the induction heating head assembly14 with respect to the workpiece 16, and so forth. Other types ofoptical detection may be utilized by the travel sensor assembly 30. Forexample, in certain embodiments, the optical sensor 220 may be opticallydirected at the workpiece 16 such that light reflecting from the surfaceof the workpiece 16 is used to detection movement of the workpiece 16relative to the optical sensor 220 (e.g., similar to a computer mouse)and, thus, the travel sensor assembly 30.

In other embodiments, as illustrated in FIG. 23, the travel sensorassembly 30 may include a tachometer 224 disposed in the housing 180 ofthe travel sensor assembly 30. The tachometer 224 may be disposedproximate to a shaft 226 that is coupled to the detection wheel 182 and,as the detection wheel 182 rotates, the tachometer 224 may determine therotational speed of the shaft 226 and, hence, the rotational speed ofthe detection wheel 182. The signals relating to this rotational speedmay be analyzed to determine the speed and direction of the inductionheating head assembly 14 relative to the workpiece 16, and so forth.

In still other embodiments, as illustrated in FIG. 24, the travel sensorassembly 30 may include an accelerometer 228 disposed in the housing 180of the travel sensor assembly 30. The accelerometer 228 may detect theacceleration of the housing 180 with respect to multiple axes and,therefore, the acceleration of the induction heating head assembly 14with respect to multiple axes. In certain embodiments, the accelerometer228 may be used in conjunction with a gyroscope. The signals relating tothese accelerations and/or gyroscopic information may be analyzed todetermine the position and/or movement (including direction of movement)of the housing 180 of the travel sensor assembly 30 relative to theworkpiece 16 in three dimensions and, therefore, the position and/ormovement (including direction of movement) of the induction heating headassembly 14 relative to the workpiece 16 in three dimensions.

These exemplary types of sensors 220, 224, 228 used by the travel sensorassembly 30 are merely exemplary and not intended to be limiting. Anyother sensor capable of detecting position and/or movement (includingdirection of movement) of the induction heating head assembly 14 may beused. Moreover, the feedback signals sent by the travel sensor assembly30 to the power source 12 relating to position and/or movement(including direction of movement) of the induction heating head assembly14 may be determined by the travel sensor assembly 30 based on signalsgenerated by more than one type of sensor of the travel sensor assembly30. For example, in certain embodiments, the travel sensor assembly 30may include both an optical sensor 220 and an accelerometer 228, and theanalysis may be based on both the signals generated by the opticalsensor 220 and the signals generated by the accelerometer 228.

As described herein, in certain embodiments, the induction heating headassembly 14 may be held in place (e.g., with respect to a supportsurface, such as the ground or floor) while the workpiece 16 is movedrelative to the induction heating head assembly 14. For example, asillustrated in FIG. 25, in embodiments where the workpiece 16 is pipe,the induction heating head assembly 14 may be held in place while thepipe is rotated while holding the outer circumference of the pipeproximate the induction heating head assembly 14, as illustrated byarrow 230. As also illustrated in FIG. 25, to facilitate holding theinduction heating head assembly 14 in a relatively fixed position withrespect to a support structure, an inductor stand 232 (i.e., inductorsupport assembly) may be used. In certain embodiments, the inductorstand 232 may include a main inductor interface body 234, which mayinclude an enclosure configured to attach to (e.g., be securely fixedto) the induction heating head assembly 14.

In certain embodiments, the main inductor interface body 234 includes agenerally cylindrical neck section 236 that has an inner diameter thatis slightly larger than an outer diameter of a first tube section 238 ofan adjustable positioning assembly 240, such as the adjustable tubeassembly illustrated in FIG. 25, such that the neck section 236 may matewith, and be fastened to, an axial end of the first tube section 238. Inother words, the axial end of the first tube section 238 may beremoveably inserted into and securely fixed to the neck section 236 ofthe main inductor interface body 234. As illustrated, in certainembodiments, the adjustable tube assembly 240 may include the first tubesection 238 (i.e., a first support member), a second tube section 242(i.e., a second support member), and a joint 244 between the first andsecond tube sections 238, 242 that enables angular adjustment withrespect to the first and second tube sections 238, 242. For example,although illustrated in FIG. 25 as being disposed generallyconcentrically with each other, the joint 244 may enable one or both ofthe first and second tube sections 238, 242 to pivot with respect to acentral axis of the joint 244, thereby adjusting an angle between axesof the first and second tube sections 238, 242.

As illustrated in FIG. 25, in certain embodiments, the second tubesection 242 of the adjustable tube 240 may fit into a generallycylindrical base tube 246 of an inductor stand base 248, which functionsas a relatively fixed support structure. The outer diameter of thesecond tube section 242 may be slightly smaller than an inner diameterof the generally cylindrical base tube 246, facilitating the second tubesection 242 mating with, and fastening to, the base tube 246. In otherwords, the second tube section 242 may be removeably inserted into andsecurely fixed to the base tube 246. As will be appreciated, a heighth_(stand) between the main inductor interface body 234 and the inductorstand base 248 may be adjusted, as illustrated by arrow 250, by varyingthe extent to which the second tube section 242 is inserted into thebase tube 246. Once a desired height h_(stand) between the main inductorinterface body 234 and the inductor stand base 248 is achieved, afastening mechanism 252, such as the knob illustrated in FIG. 25 may beused to fasten the second tube section 242 to the base tube 246. It willbe appreciated that a similar fastening mechanism 254 may be used tofasten the first tube section 238 to the neck section 236 of the maininductor interface body 234.

In certain embodiments, one or more support legs 256 may be used toprovide additional stability to the inductor stand 232. Also, in certainembodiments, three or more casters 258 may be attached to the inductorstand base 248 to enable the inductor stand 232 to be moveable fromlocation to location. Because it is desirable to maintain the inductionheating head assembly 14 in a relatively fixed position, one or more ofthe casters 258 may include a floor lock 260 to enable the respectivecaster 258 to be locked into place once the inductor stand 232 has beenmoved to a desirable location.

FIG. 26 is an exploded perspective view of an embodiment of the inductorstand 232 of FIG. 25. In certain embodiments, the main inductorinterface body 234 of the inductor stand 232 may include couplingmechanisms 262, such as the snap-in mounts illustrated in FIG. 26, whichare configured to couple the main inductor interface body 234 to theinduction heating head assembly 14. More specifically, in the embodimentillustrated in FIG. 26, the snap-in mounts 262 are configured to couplewith the crossbars 88 to attach the induction heating head assembly 14to the main inductor interface body 234. In such an embodiment, thesnap-in mounts 262 may include c-shaped bodies comprised of a materialflexible enough to snap around the crossbars 88 yet rigid enough to holdthe induction heating head assembly 14 fixed with respect to the maininductor interface body 234 once snapped around the crossbars 88. Incertain embodiments, the main inductor interface body 234 may includefour snap-in mounts 262 (e.g., two for attaching to each of the twocrossbars 88 of the induction heating head assembly 14), however, anynumber of snap-in mounts 262, or other type of coupling mechanism, maybe used. For example, in certain embodiments, the coupling mechanisms262 may include clips, clamps, brackets that attach with or withouttools, and so forth.

As illustrated in FIG. 26, in certain embodiments, the main inductorinterface body 234 may include a generally rectangular base plate 264attached to the neck section 236. One or more adjustable coupling strips266 may be selectively attached to the base plate 264 depending on thenumber and orientation of the fastening mechanisms 262 that are desiredfor the particular induction heating head assembly 14. As illustrated,each of the coupling mechanisms 262 may be attached to one of thecoupling strips 266. In certain embodiments, the coupling mechanisms 262may be fixedly attached to the coupling strips 266, while in otherembodiments, the coupling mechanisms 262 may be adjustably detachablefrom the coupling strips 266, enabling a greater degree ofcustomization. In certain embodiments, springs 268 (i.e., biasingmechanisms) may be disposed between the base plate 264 and the couplingstrips 266, thereby providing a certain degree of mobility (e.g., slightmovement) between the base plate 264 and the coupling strips 266. Incertain embodiments, the coupling strips 266 may be coupled to the baseplate 264 using bolts 270 and associated nuts 272, or some otherfastening mechanism.

As illustrated in FIG. 26, a spring 274 (i.e., biasing mechanism) may bedisposed between the neck section 236 of the main inductor interfacebody 234 and the first tube section 238 of the adjustable tube assembly240 to facilitate tensioning between the neck section 236 and the firsttube section 238. As also illustrated, in certain embodiments, thefastening mechanism 254 may be fit through an opening 276 through theneck section 236 of the main inductor interface body 234 and into ascrew hole 278 in the first tube section 238 of the adjustable tubeassembly 240 to hold the first tube section 238 in a fixed positionrelative to the neck section 236. Similarly, in certain embodiments, thefastening mechanism 252 may be fit through an opening 280 through thebase tube 246 and into a screw hole 282 in the second tube section 242of the adjustable tube assembly 240 to hold the second tube section 242in a fixed position relative to the base tube 246. As also illustrated,in certain embodiments, a crossbar 284 may be associated with one ormore support leg 256 to provide even further stability to the supportleg 256 with respect to the inductor stand base 248 and the base tube246.

FIG. 27 is a perspective view of another embodiment of the inductorstand 232 that may be used to hold the induction heating head assembly14 in a relatively fixed position. In the illustrated embodiment, themain inductor interface body 234 includes a top section 286 and a bottomsection 288 that are configured to interface with each other and enableslight movement between the top section 286 and a bottom section 288 tomitigate adverse effects of vibrations, jostling, etc. Morespecifically, as illustrated in FIG. 28, in certain embodiments, the topand bottom sections 286, 288 of the main inductor interface body 234 mayinclude respective side walls 290, 292 that are configured to slideslightly relative to each other. For example, in certain embodiments,alignment pins 294 may remain relatively fixed with respect to (and,indeed, may be attached to) one of the side walls 290, 292 (e.g., theside walls 290 of the top section 286 in the illustrated embodiment)while being able to slide relative to alignment slots 296 through theother of the adjacent side walls 290, 292 (e.g., through the side walls292 of the bottom section 288 in the illustrated embodiment). Althoughillustrated as only having opposing side walls 290, 292, it will beappreciated that in other embodiments, the side walls 290, 292 mayextend entirely around the main inductor interface body 234 (e.g.,entirely isolating the internal components of the main inductorinterface body 234 from the surrounding environment).

As illustrated in FIGS. 27 and 28, in certain embodiments, one or moresleeves 298 may be disposed between the top and bottom sections 286, 288of the main inductor interface body 234. Although illustrated asincluding four sleeves 298 (e.g., near each of the four corners of therectangular-shaped main inductor interface body 234), in otherembodiments, any number of sleeves 298 may be used. For illustrationpurposes, one of the sleeves 298 has been removed to show how thesleeves 298 interact with the top and bottom sections 286, 288 of themain inductor interface body 234. In particular, as illustrated in FIG.28, in certain embodiments, each of the sleeves 298 may interact withrespective alignment pegs 300, 302 of the top and bottom sections 286,288 of the main inductor interface body 234 to maintain alignment of thesleeves 298 between the top and bottom sections 286, 288. Morespecifically, in certain embodiments, the sleeves 298 may include hollowinteriors such that walls of the sleeves 298 fit around the alignmentpegs 300, 302. In addition, in certain embodiments, one or more of thesleeves 298 may include a spring 304 (i.e., biasing mechanism) disposedwithin the walls of the sleeves 298. In certain embodiments, the springs304 may be slightly longer axially than the sleeves 298 such that thesprings 304 may directly interact with the top and bottom sections 286,288 of the main inductor interface body 234 to enable a certain degreeof motion relative to the top and bottom sections 286, 288, thusaccommodating for physical irregularities in the workpiece 16 as theinduction heating head assembly 14 traverses the workpiece 16. It willbe appreciated that the springs 304 also bias the induction heating headassembly 14 toward the workpiece 16. In certain embodiments, instead ofsprings 304, other types of biasing mechanisms may be used, such ascounterweights, etc.

Returning now to FIG. 27, in certain embodiments, the adjustable tubeassembly 240 may function slightly differently than the adjustable tubeassembly 240 of the embodiment illustrated in FIGS. 25 and 26. Morespecifically, in certain embodiments, the adjustable tube assembly 240may include a tube section 306 (i.e., support member) that is configuredto fit into the base tube 246 of the inductor stand 232 (e.g., similarto the second tube section 242 of the adjustable tube assembly 240 ofFIGS. 25 and 26) and that has an opposite axial end 308 that isconfigured to interact with (e.g., selectively engage) an angularalignment plate 310 that is attached to the bottom section 288 of themain inductor interface body 234 to facilitate angular re-positioning ofthe main inductor interface body 234 (and, thus, the induction heatinghead assembly 14) with respect to the inductor stand 232, as illustratedby arrow 312. In certain embodiments, the tube section 306 is configuredto rotate about an axis 309 of the tube section 306 and the base tube246, as illustrated by arrow 311. In particular, a slot and one or moremating grooves on an exterior surface of the tube section 306 and aninterior surface of the base tube 246, respectively, may enable the tubesection 306 to be selectively rotated between a plurality of fixedpositions with respect to the base tube 246 to facilitate furthercustomization of the positioning of the induction heating head assembly14 with respect to the base tube 246. Alternatively, a groove and one ormore mating slots on an exterior surface of the tube section 306 and aninterior surface of the base tube 246, respectively, may be used toselectively position the tube section 306 with respect to the base tube246.

FIG. 29 is a partial cutaway perspective view illustrating how the axialend 308 of the tube section 306 of the adjustable tube assembly 240interacts with the angular alignment plate 310 of the main inductorinterface body 234. It will be appreciated that part of the exteriorsurface of the axial end 308 of the tube section 306 has been removedfor illustration purposes. As illustrated, in certain embodiments, afirst (e.g., fixed alignment) pin 314 may extend through both the axialend 308 of the tube section 306 and the angular alignment plate 310 ofthe main inductor interface body 234 to hold the tube section 306 andthe angular alignment plate 310 relatively fixed with respect to eachother along an axis 316 of the alignment pin 314. However, a second(e.g., adjustable alignment) pin 318 may enable adjustment of an angularorientation of the angular alignment plate 310 (and, thus, the maininductor interface body 234 and the induction heating head assembly 14)with respect to the tube section 306 (and, thus, the inductor stand232). In particular, in certain embodiments, the semi-circular angularalignment plate 310 may include a plurality of openings 320 throughwhich the adjustable alignment pin 318 may be selectively inserted toadjust the angular orientation of the angular alignment plate 310 withrespect to the tube section 306. As such, the openings 320 function as afirst alignment feature and the adjustable alignment pin functions as asecond alignment feature. In other embodiments, other types of alignmentfeatures may be used, such as slots, friction plates, and so forth.

Returning now to FIG. 27, as illustrated, in certain embodiments, theinductor stand 232 may not include an inductor stand base 248 such asthe embodiment illustrated in FIGS. 25 and 26. Rather, in certainembodiments, the base tube 246 may include an elongated body 322 that isattached to the plurality of support legs 256 with a plurality ofrespective crossbars 284 that provide additional support between thebase tube 246 and the support legs 256. Although illustrated in FIG. 27as not including casters 258 and floor locks 260 associated with thesupport legs 256, it will be appreciated that in certain embodiments,the support legs 256 may indeed be associated with respective casters258 and, in certain embodiments, floor locks 260. Furthermore, incertain embodiments, the adjustable tube assembly 240 may not beattached to an inductor stand base, as illustrated in FIGS. 25-27.Rather, in certain embodiments, the adjustable tube assembly 240 mayinstead be attached to an alternate support structure, such as an arm orbeam that remains in a relatively fixed position. Furthermore, incertain embodiments, the adjustable tube assembly 240 may be attached toa relatively fixed support structure, such as a gantry system, that iscapable of movement, but that is configured to hold the adjustable tubeassembly 240 in a fixed position when desired.

It should be noted that, although described herein as enablingadjustment of both a height of the main inductor interface body 234(and, thus, the induction heating head assembly 14) from a relativelyfixed support structure, such as the inductor stand base, as well as anangular orientation of the main inductor interface body 234 (and, thus,the induction heating head assembly 14) with respect to the relativelyfixed support structure, in other embodiments, only the height of themain inductor interface body 234 from the relatively fixed supportstructure or the angular orientation of the main inductor interface body234 with respect to the relatively fixed support structure may beadjustable. For example, in certain embodiments, the inductor stand 232may not include either of the common joint 244 between the first andsecond tube sections 238, 242 (see, e.g., FIG. 26) or the angularalignment plate 310 (see, e.g., FIG. 27) and, thus, may not beconfigured to adjust the angular orientation of the main inductorinterface body 234 with respect to the relatively fixed supportstructure. Furthermore, in other embodiments, the tube sections 238,242, 306 (see, e.g., FIGS. 26 and 27) of the adjustable tube assembly240 may not be configured to translate into and out of the base tube 246and, thus, may not be configured to adjust the height of the maininductor interface body 234 from the relatively fixed support structure.In still other embodiments, neither the height of the main inductorinterface body 234 from the relatively fixed support structure nor theangular orientation of the main inductor interface body 234 with respectto the relatively fixed support structure may be adjustable. It will beunderstand that, even in such embodiments, the biasing members (e.g.,elements 304 illustrated in FIG. 28) and other components of theinductor stand 232 may enable slight movement of the main inductorinterface body 234 with respect to the inductor stand 232. As such,physical irregularities in the workpiece 16 may be accommodated moreeasily due to these components. Furthermore, these components enable themain inductor interface body 234 (and, thus, the induction heating headassembly 14) to be biased against the workpiece 16.

FIG. 30 is a perspective view of an exemplary embodiment of the powersource 12 that is configured to operate with the induction heating headassembly 14, the temperature sensor assembly or assemblies 28, and/orthe travel sensor assembly 30 as described herein. As illustrated, incertain embodiments, a removable connection box 324 and/or a removableair filter assembly 326 may be removably coupled (e.g., in separatehousings) to the power source 12 to enable the connections thatfacilitate the power source 12 operating with the induction heating headassembly 14, the temperature sensor assembly or assemblies 28, and/orthe travel sensor assembly 30.

FIGS. 31 and 32 are zoomed in perspective views of the connection box324 and the air filter assembly 326 of FIG. 30. As illustrated in FIG.31, in certain embodiments, the connection box 324 includes a travelsensor connection 328 that may receive (e.g., travel feedback) signalsfrom the travel sensor assembly 30 (e.g., via the cable 20 illustratedin FIG. 1). In certain embodiments, the connection box 324 also includesan output connection 330 that may transmit signals from the connectionbox 324 to other connectors on the power source 12 or to a system (e.g.,a robotic positioning system for controlling movement of the inductionheating head assembly 14 or controlling movement of the workpiece 16relative to the induction heating head assembly 14, an externalprocessing device, and so forth) separate from the power source 12. Inaddition, in certain embodiments, the connection box 324 includes firstand second auxiliary electrical lead connection blocks 332, 334 forconnecting to auxiliary electrical leads, for example, thermocoupleleads and other sensor leads. In addition, in certain embodiments, theconnection box 324 may include some or all of the control circuitrydescribed as being part of the power source with respect to FIG. 2. Forexample, in certain embodiments, the connection box 324 may include thecontroller circuitry 50, which controls the power conversion circuitry46, 48, 52, among other things, to adjust the induction heating poweroutput 54 provided by the power source 12.

Furthermore, as illustrated in FIG. 32, in certain embodiments, theconnection box 324 includes first and second temperature sensorconnections 336, 338 that may receive (e.g., temperature feedback)signals from first and second temperature sensor assemblies 28 (e.g.,via the cable 18 illustrated in FIG. 1 and similar cables). In certainembodiments, more than two temperature sensor connections 336, 338 maybe used. As illustrated, only one cable 18 connecting a temperaturesensor assembly 28 is connected to the connection box 324 via the firsttemperature sensor connection 336; however, a second temperature sensorassembly 28 may also be connected via the second temperature sensorconnection 338. In addition, in certain embodiments, the connection box324 may include first and second temperature lead connection blocks 340,342 for connecting to electrical leads, for example, thermocouple leadsconveying signals related to temperatures internal to one or moreinduction heating head assemblies 14. As illustrated, only onetemperature lead connection block 340 is being utilized; however, thesecond temperature lead connection block 342 may also be utilized toreceive temperature signals from a second induction heating headassembly 14.

As illustrated in FIGS. 31 and 32, in certain embodiments, the airfilter assembly 326 includes an oil separator 344 and/or a waterseparator 346 for removing oil and/or water from shop air that isreceived by the power source 12 via a separate connection (not shown).The oil and water may be discharged via an oil outlet 348 and a wateroutlet 350, respectively. In certain embodiments, the air filterassembly 326 also includes an air regulator for regulating the flow ofair through the air filter assembly 326. The processed air (e.g., afterremoval of the oil and/or water) is delivered to the temperature sensorassembly 28 (e.g., via an air cable to the air cable connector 70 of thetemperature sensor assembly 28) through an air outlet 352. In instanceswhere more than one temperature sensor assembly 28 is used, a splitter(not shown) may be used to split the flow of processed air for deliveryto the multiple temperature sensor assemblies 28.

FIG. 33A is a perspective view of the connection box 324 with an accessdoor 354 of the connection box 324 removed for illustration purposes. Inaddition, FIG. 33B is an exploded perspective view of the connection box324, which illustrates how a circuit board 356 is mounted inside theaccess door 354 (e.g., attached to the access door 354 via a pluralityof fastening mechanisms 355, such as screws, in certain embodiments). Asillustrated, in certain embodiments, a plurality of fastening mechanisms357, such as screws, may also be used to fasten the access door 354 tothe connection box 324 (e.g., instead of, or in addition to, includingan access door 354 that may be opened via hinges, and so forth). Thecircuit board 356 includes circuitry configured to receive input signalsfrom the travel sensor connection 328, the first and second auxiliaryelectrical lead connection blocks 332, 334, the first and secondtemperature sensor connections 336, 338, and the first and secondtemperature lead connection blocks 340, 342, to perform certain signalprocessing on at least some of the input signals, and to transmit outputsignals via the output connection 330 and a plurality of connectionblocks 358 on a back side (e.g., a side opposite the access door 354) ofthe connection box 324. It will be appreciated that the circuit board356 is communicatively coupled (e.g., via wiring and/or other electricalconnections) to the travel sensor connection 328, the first and secondauxiliary electrical lead connection blocks 332, 334, the first andsecond temperature sensor connections 336, 338, the first and secondtemperature lead connection blocks 340, 342, the output connection 330,the plurality of connection blocks 358, and so forth.

The plurality of connection blocks 358 are configured to communicativelycouple to a matching plurality of connection blocks 360 disposed on anexterior of the power source 12 (as illustrated in FIG. 34). It will beappreciated that the plurality of connection blocks 360 of the powersource 12 are, in turn, communicatively coupled to the controllercircuitry 50 (see FIG. 2) of the power source 12 to enable thecontroller circuitry 50 to adjust the output power 54 supplied to theinduction heating head assembly 14 based on the signals received andprocessed by the connection box 324. In the illustrated embodiment, theconnection box 324 includes six connection blocks 358 for connecting tosix mating connection blocks 360 on the power source 12; however,different numbers of connection blocks 358, 360 may be utilized.

As illustrated, in certain embodiments, the first and second temperaturesensor connections 336, 338 and the first and second temperature leadconnection blocks 340, 342 are disposed on a first lateral side of ahousing of the connection box 324, the first and second auxiliaryelectrical lead connection blocks 332, 334 are disposed on a secondlateral side of the housing of the connection box 324 opposite the firstlateral side, the travel sensor connection 328 and the output connection330 are disposed on a third lateral side of the housing of theconnection box 324, and the plurality of connection blocks 358 aredisposed on a back side of the housing of the connection box 324.However, the locations of all of these connections 328, 330, 336, 338and connection blocks 332, 334, 340, 342 may vary between embodiments.

In certain embodiments, the six connection blocks 358 are configured tooutput signals corresponding to the input signals received by theconnection box 324 via the first and second auxiliary electrical leadconnection blocks 332, 334, the first and second temperature sensorconnections 336, 338, and the first and second temperature leadconnection blocks 340, 342. In such an embodiment, the input signalsreceived via the first and second auxiliary electrical lead connectionblocks 332, 334 may simply be passed through by the circuitry 356 of theconnection box 324 to two corresponding connection blocks 358.Similarly, the input signals received via the first and secondtemperature lead connection blocks 340, 342 may also be passed throughby the circuitry 356 of the connection box 324 to two correspondingconnection blocks 358. However, the circuitry 356 of the connection box324 may perform certain processing of the input signals received fromthe first and second temperature sensor connections 336, 338 beforetransmitting the processed signals as output signals to the power source12 via two corresponding connection blocks 358. Similarly, in certainembodiments, the circuitry 356 of the connection box 324 may performcertain processing of the input signals received from the travel sensorconnection 328 before transmitting the processed signals as outputsignals via the output connection 330.

For example, in certain embodiments, the circuitry of the circuit board356 may be configured to receive the input (e.g., temperature feedback)signals via the first and second temperature sensor connections 336, 338and process these input signals to generate output signals that may beproperly interpreted by the controller circuitry 50 (see FIG. 2) of thepower source 12. For example, the power source 12 may expect to receivesignals relating to temperature readings in a Type K thermocouple range(or other type of thermocouple range, such as Type T), which may be onthe order of microvolts and microamps, whereas the temperature sensorassemblies 28 transmit signals on the order of 4-20 milliamps, forexample. As such, the circuitry of the circuit board 356 may scale theinput signals received via the first and second temperature sensorconnections 336, 338 from the 4-20 milliamp scale to a lower amperage orvoltage range that may properly be interpreted by the controllercircuitry 50 of the power source 12. In addition, in certainembodiments, the circuitry of the circuit board 356 may add an offset tothe input signals received via the first and second temperature sensorconnections 336, 338 to compensate for an offset that is implemented bythe controller circuitry 50 of the power source 12. In certainembodiments, the internal temperature of the connection box 324 may bedetected (e.g., using a temperature sensor connected to the connectionbox 324 via the auxiliary electrical lead connection blocks 332, 334 incertain embodiments) and used in the determination of an appropriateoffset. In other embodiments, the temperature may be measured using achip on the circuit board 356, and an appropriate offset may bedetermined based on this measured temperature. Therefore, the circuitryof the circuit board 356 converts the input (e.g., temperature feedback)signals received via the first and second temperature sensor connections336, 338 to appropriate output signals for use by the controllercircuitry 50 of the power source 12 (e.g., to mimic a thermocouple). Inaddition, in certain embodiments, the circuit board 356 may performlocal calculations on the input (e.g., temperature feedback) signalsreceived via the first and second temperature sensor connections 336,338, filter the input (e.g., temperature feedback) signals received viathe first and second temperature sensor connections 336, 338, and soforth.

Furthermore, in certain embodiments, the circuitry of the circuit board356 may similarly convert (e.g., scale, offset, and so forth) the input(e.g., travel feedback) signals received via the travel sensorconnection 328 to appropriate output signals for use by the controllercircuitry 50 of the power source 12. In addition, in certainembodiments, the circuit board 356 may perform local calculations on theinput (e.g., travel feedback) signals received via the travel sensorconnection 328, filter the input (e.g., travel feedback) signalsreceived via the travel sensor connection 328, and so forth.

In addition, as illustrated in FIGS. 31 and 32, in certain embodiments,the connection box 324 may include one or more indicators 361 forindicating temperatures corresponding to the input signals receive viathe first and second temperature sensor connections 336, 338,respectively. In certain embodiments, the indicators 361 may be lightemitting diodes configured to illuminate various colors corresponding tocertain temperature ranges (e.g., red if the corresponding temperatureis above a maximum temperature threshold or below a minimum temperaturethreshold, green if the corresponding temperature is within anacceptable temperature range, and so forth).

It will be appreciated that the connection box 324 may be particularlyuseful for retrofitting older power sources with the capability tofunction with the travel sensor assembly 28 and/or the travel sensorassembly 30. In particular, the circuit board 356 of the connection box324 may perform all of the conversions necessary to present the olderpower sources with the types of signals it expects. Furthermore,different embodiments of the connection box 324 may be particularly wellsuited for use with certain types of power sources (e.g., that haveparticular types of connections).

In certain embodiments, instead of being disposed in a connection box324 having all of the physical connections described herein, the circuitboard 356 may be used as a separate component that may reside innumerous places (e.g., within the power source 12, within a separateenclosure having none of the connections of the connection box 324,within the induction heating head assembly 14 (e.g., within the cablestrain relief cover 24), and so forth), and may include wirelesscommunication circuitry configured to send and receive signalswirelessly to and from wireless communication circuitry of the inductionheating head assembly 14, the temperature sensor assembly 28, the travelsensor assembly 30, the power source 12, and so forth. In otherembodiments, the circuit board 356 may still be enclosed within theconnection box 324, however, certain of the connections may not bedisposed on the enclosure of the connection box 324, but rather may bereplaced by the wireless communication circuitry of the circuit board356. In one non-limiting example, the connection box 324 may not includethe first and second temperature sensor connections 336, 338, and thecircuit board 356 may receive input (e.g., temperature feedback) signalsfrom first and second temperature sensor assemblies 28 wirelessly viaits wireless communication circuitry. In another non-limiting example,the connection box 324 may include all of the input connections but noneof the output connections, and the circuit board 356 may insteadtransmit output signals to the power source 12 wirelessly via itswireless communication circuitry.

As described herein, the temperature sensor assembly 28 providesfeedback signals relating to temperature of the workpiece 16 to thecontroller circuitry 50 of the power source 12 and the travel sensorassembly 30 provides feedback signals relating to position and/ormovement of the travel sensor assembly 30 with respect to the workpiece16 to the controller circuitry 50. The controller circuitry 50 uses thefeedback signals from the temperature sensor assembly 28 and the travelsensor assembly 30 to modify the output power 54 provided to theinduction heating head assembly 14 for the purpose of providinginduction heat to the workpiece 16. Returning to FIG. 2, the controllercircuitry 50 of the power source 12 may include instructions formodifying (e.g., adjusting) the output power 54 provided to theinduction heating head assembly 14 for the purpose of induction heatingthe workpiece 16 based at least in part on the feedback signals receivedfrom the temperature sensor assembly 28 and/or the travel sensorassembly 30.

In certain embodiments, modification (e.g., adjustment) of the outputpower 54 is dependent upon the feedback provided by the travel sensorassembly 30, although in other embodiments, the controller circuitry 50may be capable of controlling the output power 54 with or without beingcommunicatively coupled to the travel sensor assembly 30. In certainembodiments, the output power 54 may be reduced (e.g., throttled), oreven eliminated, when the travel sensor assembly 30 detects little or nomovement of the travel sensor assembly 30 relative to the workpiece 16.In particular, the instructions stored in the controller circuitry 50may include instructions for reducing, or even eliminating, the outputpower 54 when a feedback signal is sent from the travel sensor assembly30 and received by the controller circuitry 50 that indicates thatlittle or no movement of the travel sensor assembly 30 relative to theworkpiece 16 has been detected by the travel sensor assembly 30 for agiven period of time. Furthermore, in certain embodiments, the outputpower 54 may be reduced, or even eliminated, when the travel sensorassembly 30 is not communicatively coupled to the controller circuitry50 (e.g., via the cable 20 illustrated in FIG. 1). In particular, theinstructions stored in the controller circuitry 50 may includeinstructions for reducing, or even eliminating, the output power 54 whena feedback signal is not received from the travel sensor assembly 30 fora given period of time.

In certain embodiments, modification (e.g., adjustment) of the outputpower 54 may be based at least in part on a speed (e.g., velocity) ofthe travel sensor assembly 30 with respect to the workpiece 16, or viceversa. As such, the instructions stored in the controller circuitry 50may include instructions for modifying the output power 54 based atleast in part on the feedback signals received from the travel sensorassembly 30 when the feedback signals include data indicative of thespeed of the travel sensor assembly 30 with respect to the workpiece 16,or vice versa. In other embodiments, modification (e.g., adjustment) ofthe output power 54 may be based at least in part on a direction oftravel of the travel sensor assembly 30 with respect to the workpiece16, or vice versa. As such, the instructions stored in the controllercircuitry 50 may include instructions for modifying the output power 54based at least in part on the feedback signals received from the travelsensor assembly 30 when the feedback signals include data indicative ofthe direction of travel of the travel sensor assembly 30 with respect tothe workpiece 16, or vice versa. The speed (e.g., velocity) anddirection of travel of the travel sensor assembly 30 relative to theworkpiece 16 are merely exemplary, and not intended to be limiting, ofthe types of parameters relating to position and/or movement (includingdirection of movement) of the travel sensor assembly 30 relative to theworkpiece 16 that may be used by the controller circuitry 50 to modifythe output power 54. Data relating to other parameters, such as absoluteposition of the travel sensor assembly 30 relative to the workpiece 16,acceleration of the travel sensor assembly 30 relative to the workpiece16, orientation differences of the travel sensor assembly 30 relative tothe workpiece 16, and so forth, may be received from the travel sensorassembly 30 by the controller circuitry 50, and used by the controllercircuitry 50 to control the output power 54 of the power source 12 thatis delivered to the induction heating head assembly 14.

In certain embodiments, the controller circuitry 50 may receive thefeedback signals from the temperature sensor assembly 28 and interpretthe temperature readings provided via the feedback signals to find thebest one (e.g., compare the readings to other temperature readings todetermine correlation, etc.). In general, when the controller circuitry50 is connected to the temperature sensor assembly 28, the controllercircuitry 50 controls the output power 54 of the power source 12 basedat least in part on the feedback signals received from the temperaturesensor assembly 28. In particular, in certain embodiments, thecontroller circuitry 50 may follow a temperature ramp to reach asetpoint temperature of the workpiece 16 that may, for example, be setby a user via the control panel 362 of the power source 12. For example,FIG. 35 is a graph of an exemplary temperature ramp 364 that thecontroller circuitry 50 may utilize while controlling the output power54 delivered by the power source 12. As illustrated, in certainembodiments, the temperature ramp 364 may be a relatively lineartwo-stage ramp from an initial temperature τ₀ to a target temperatureτ_(target). More specifically, a first temperature ramp stage 366 may befollowed until a temperature threshold τ_(threshold) (e.g., a setpercentage of the target temperature τ_(target)) is reached, at whichpoint a second, more gradual temperature ramp stage 368 may be followedto minimize the possibility of overshooting the target temperatureτ_(target). However, in other embodiments, other types of temperatureramps (e.g., relatively asymptotic, and so forth) may be utilized by thecontroller circuitry 50. It will be appreciated that, while followingthe temperature ramp 364, if a given temperature reading T1 falls belowits expected value for a given time (e.g., time 1) on the temperatureramp 364, the controller circuitry 50 may increase the output power 54,whereas if a given temperature reading τ₂ falls above its expected valuefor a given time (e.g., time 2) on the temperature ramp 364, thecontroller circuitry 50 may decrease the output power 54. In certainembodiments, the controller circuitry 50 may use closed loop control toreach the target temperature τ_(target).

As such, the controller circuitry 50 may control the output power 54based at least in part on travel speed and/or direction of travel of theworkpiece 16 relative to the induction heating head assembly 14 (asdetected by the travel sensor assembly 30). As a non-limiting example ofsuch control, as the travel speed increases, the output power 54 may beincreased, and as the travel speed decreases, the output power 54 may bedecreased. In addition, in certain embodiments, the controller circuitry50 may control the output power 54 based at least in part on thetemperature(s) of the workpiece 16 (as detected by the temperaturesensor assembly 28 or multiple temperature sensor assemblies 28), forexample, according to the temperature ramp 364 illustrated in FIG. 35.In addition, in certain embodiments, the controller circuitry 50 maycontrol the output power 54 based at least in part on the amount of timethe workpiece 16 has been heated. It will be appreciated that thecontroller circuitry 50 may control the output power 54 based at leastin part on parameters relating to the output power 54 (e.g., previous orcurrent output parameters relating to the power, amperage frequency,duty cycle, and so forth, of the output power 54). The operatingparameters described herein as being used by the controller circuitry 50to modify the control of the output power 54 are merely exemplary andnot intended to be limiting. In certain embodiments, data relating toany and all of these operating parameters may be indicated via a controlpanel 362 (e.g., on a display) of the power source 12. In addition, incertain embodiments, the induction heating head assembly 14 may alsoinclude a means (e.g., control panel and/or display) for indicating datarelating to these operating parameters.

In certain embodiments, the controller circuitry 50 may determinecharacteristics of the workpiece 16 based at least in part on the inputsignals received from the temperature sensor assembly or assemblies 28,the travel sensor assembly 30, the induction heating head assembly 14,and so forth, including but not limited to travel speed and/or directionof travel of the workpiece 16 relative to the travel sensor assembly 30,temperature(s) of the workpiece 16, heating time of the workpiece 16,previous output power 54, current output power 54, and so forth.

In certain embodiments, control of the output power 54 in general may bebased at least in part on operating parameters entered by a user via thecontrol panel 362 of the power source 12 including, but not limited to,dimensions of the workpiece 16, material of the workpiece 16, and soforth. In addition, in certain embodiments, control of the output power54 in general may be based at least in part on data gathered from theheating process (e.g., from the induction heating head assembly 14)including, but not limited to, voltage of the output power 54, currentof the output power 54, frequency of the output power 54, power factor,primary current, current measured within the power source 12, coolanttemperature, an internal temperature of the induction heating headassembly 14, and so forth. In certain embodiments, control of the outputpower 54 in general may be based at least in part on user heatingpreferences that may, for example, be entered via the control panel 362of the power source 12 including, but not limited to, desiredtemperature ramp speed, acceptable temperature overshoot, preference forgentle vs. aggressive heating, and so forth. As a non-limiting example,if a user wishes to heat a pipe very carefully, and does not care howlong it takes, the user could set the induction heating mode to “gentle”and/or could set an acceptable temperature overshoot of zero and/orcould set the temperature ramp speed to “slow.”

In certain embodiments, the controller circuitry 50 of the power source12 is configured to display the data (e.g., temperature, heat input, andso forth) detected by the temperature sensor assembly or assemblies 28and/or the data (travel speed, direction of travel, and so forth)detected by the travel sensor assembly 30 via the control panel 362 ofthe power source 12. In addition, in certain embodiments, the connectionbox 324 may include a display, and the circuitry of the circuit board356 of the connection box 324 may be configured to display the data(e.g., temperature, heat input, and so forth) detected by thetemperature sensor assembly or assemblies 28 and/or the data (travelspeed, direction of travel, and so forth) detected by the travel sensorassembly 30 via such display. Furthermore, in certain embodiments, thecontroller circuitry 50 of the power source 12 is configured to storethe data (e.g., temperature, heat input, and so forth) detected by thetemperature sensor assembly or assemblies 28 and/or the data (travelspeed, direction of travel, and so forth) detected by the travel sensorassembly 30 in the memory 60. In addition, in certain embodiments, theconnection box 324 may include a non-transitory memory medium similar tothe memory 60 of the controller circuitry 50, and the circuitry of thecircuit board 356 of the connection box 324 may be configured to storethe data (e.g., temperature, heat input, and so forth) detected by thetemperature sensor assembly or assemblies 28 and/or the data (travelspeed, direction of travel, and so forth) detected by the travel sensorassembly 30 in such a memory medium. Moreover, in certain embodiments,the data (e.g., temperature, heat input, and so forth) detected by thetemperature sensor assembly or assemblies 28 and/or the data (travelspeed, direction of travel, and so forth) detected by the travel sensorassembly 30 may be stored in a remote location from the power source 12and/or the connection box 324, for example, via cloud storage or aserver connected to a network to which the power source 12 and/or theconnection box 324 are communicatively connected.

In certain embodiments, the controller circuitry 50 of the power source12 may be configured to automatically detect (e.g., without input from ahuman operator) whether the temperature sensor assembly or assemblies28, the travel sensor assembly 30, and/or the induction heating headassembly 14 are connected (e.g., communicatively coupled) to thecontroller circuitry 50 (e.g., either directly or via the connection box324), and to automatically modify (e.g., without input from a humanoperator) operation (i.e., adjust control of operating modes, modify acontrol algorithm, adjust certain operating parameters, and so forth) ofthe power source 12 based on the determination (e.g., which devices aredetected as being communicatively coupled to the control circuitry 50,what particular types of the devices (e.g., between temperature sensorassemblies 28 configured to detect temperatures at certain wavelengthsrelating to certain emissivities, between travel sensor assemblies 30that use particular types of sensors, and so forth) are communicativelycoupled to the control circuitry 50, and so forth). As a non-limitingexample, the controller circuitry 50 may automatically switch to an“induction heating head mode” when the induction heating head assembly14 is detected as being connected to the power source 12.

In addition, the controller circuitry 50 described herein is configuredto function in various modes, depending on what devices arecommunicatively coupled to the controller circuitry 50. In certainembodiments, the controller circuitry 50 may control the power source 12only when the induction heating head assembly 14 is communicativelycoupled to the controller circuitry 50. However, the controllercircuitry 50 may control the power source 12 when a temperature sensorassembly 28 is communicatively coupled to the controller circuitry 50but a travel sensor assembly 30 is not communicatively coupled to thecontroller circuitry 50, when a travel sensor assembly 30 iscommunicatively coupled to the controller circuitry 50 but a temperaturesensor assembly 28 is not communicatively coupled to the controllercircuitry 50, when both a temperature sensor assembly 28 and a travelsensor assembly 30 are communicatively coupled to the controllercircuitry 50, and so forth.

In addition, although described herein as being configured to sendfeedback signals to the controller circuitry 50 for the purpose ofcontrolling the power source 12, in certain embodiments, the temperaturesensor assembly and/or the travel sensor assembly 30 described hereinmay, in addition to or alternatively, be configured to indicateinformation relating to the detected parameter (e.g., temperature of theworkpiece 16 for the temperature sensor assembly 28 and position,movement, or direction of movement of the induction heating headassembly 14 relative to the workpiece 16 for the travel sensor assembly30) on the respective device (e.g., via LEDS, a display, and so forth),to log the information relating to the detected parameter (e.g., storelocally in memory or transmit to a separate storage device or cloud forstorage), perform a local calculation based at least in part on theinformation relating to the detected parameter, and so forth.

Returning now to FIG. 2, in certain embodiments, the controllercircuitry 50 of the power source 12 may be configured to send (e.g.,either through a wired connection or wirelessly) instructions to arobotic positioning system 370 that is configured to control movement ofthe induction heating head assembly 14 relative to the workpiece 16 orto control movement of the workpiece 16 relative to the inductionheating head assembly 14 based at least in part on the signals receivedfrom the temperature sensor assembly or assemblies 28, the travel sensorassembly 30, the induction heating head assembly 14, and/or the userpreferences set by the user via the control panel 362 of the powersource 12, and/or any and all other information received by thecontroller circuitry 50. However, in other embodiments, the controltechniques described herein may also be implemented when the inductionheating head assembly 14 is being held by a human operator. As alsoillustrated in FIG. 2, in certain embodiments, the output power 54provided to the induction heating head assembly 14 may be at leastpartially controlled using a remote control 372, which may communicatewith the controller circuitry 50 of the power source 12 either through awired connection or wirelessly.

In addition, although described herein as including an induction heatinghead assembly 14, it will be appreciated that the temperature sensorassembly 28, the travel sensor assembly 30, the controller circuitry 50,the connection box 324, the inductor stand 232, the control techniques,and so forth, described herein may function substantially similarly whenother types of workpiece heating devices are used. For example, incertain embodiments, instead of an induction heating head assembly 14,the workpiece heating device may be an infrared heating deviceconfigured to generate infrared heat on the workpiece 16. Indeed, anyworkpiece heating device capable of generating contacting ornon-contacting localized heating of workpieces for fabrication maybenefit from the systems and methods described herein.

While only certain features of the disclosure have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes.

1. An induction heating system comprising: an induction heating deviceconfigured to move relative to a workpiece, to generate induction heat,and to direct the induction heat to the workpiece; and a travel sensorassembly configured to detect a position, movement, or direction ofmovement of the induction heating device relative to the workpiece, thetravel sensor comprising a non-contacting detector.
 2. The inductionheating system of claim 1, wherein the travel sensor assembly isconfigured to transmit a feedback signal relating to the detectedposition, movement, or direction of movement to a controller thatcontrols a power source providing power to the induction heating device.3. The induction heating system of claim 2, further comprising thecontroller, wherein the controller is configured to adjust an amount ofpower provided by the power source to the induction heating device basedat least in part on the feedback signal.
 4. The induction heating systemof claim 3, wherein the controller is configured to automatically detectwhen the travel sensor assembly is communicatively coupled to thecontroller, and to automatically adjust control of the power sourcebased on the detection of the travel sensor assembly.
 5. The inductionheating system of claim 3, wherein the controller is configured toadjust the amount of power provided by the power source to the inductionheating device based at least in part on parameters of a weldingoperation performed on the workpiece.
 6. The induction heating system ofclaim 1, wherein the non-contacting detector comprises a magnetic sensorconfigured to detect the position, movement, or direction of movement.7. The induction heating system of claim 1, wherein the non-contactingdetector comprises an accelerometer configured to detect the position,movement, or direction of movement.
 8. The induction heating system ofclaim 1, wherein the non-contacting detector comprises an optical sensorconfigured to detect the position, movement, or direction of movement.9. The induction heating system of claim 1, wherein the travel sensorassembly is removably detachable from a housing of the induction heatingdevice.
 10. A travel sensor assembly, comprising a non-contactingdetector configured to detect a position, movement, or direction ofmovement of an induction heating device relative to a workpiece, thetravel sensor assembly configured to transmit a feedback signal relatingto the detected position, movement, or direction of movement to acontroller that controls a power source providing power to the inductionheating device.
 11. The travel sensor assembly of claim 10, furthercomprising the controller, wherein the controller is configured toadjust an amount of power provided by the power source to the inductionheating device based at least in part on the feedback signal.
 12. Thetravel sensor assembly of claim 11, wherein the controller is configuredto automatically detect when the travel sensor assembly iscommunicatively coupled to the controller, and to automatically adjustcontrol of the power source based on the detection of the travel sensorassembly.
 13. The travel sensor assembly of claim 11, wherein thecontroller is configured to adjust the amount of power provided by thepower source to the induction heating device based at least in part onparameters of a welding operation performed on the workpiece.
 14. Thetravel sensor assembly of claim 10, wherein the non-contacting detectorcomprises a magnetic sensor configured to detect the position, movement,or direction of movement.
 15. The travel sensor assembly of claim 10,wherein the non-contacting detector comprises an accelerometerconfigured to detect the position, movement, or direction of movement.16. The travel sensor assembly of claim 10, wherein the non-contactingdetector comprises an optical sensor configured to detect the position,movement, or direction of movement.
 17. The travel sensor assembly ofclaim 10, wherein the travel sensor assembly is removably detachablefrom a housing of the induction heating device.